Heat and energy recovery and regeneration assembly, system and method

ABSTRACT

A heat recovery system including a chamber having a cooling intake, an emissions intake, and a chamber exhaust, a heat recovery exchanger, a fluid circuit in communication with the heat recovery exchanger, a heat extraction exchanger, at least one controller operably linked to at least one operating component of the heat recovery system and at least one sensor configured to collect at least one environmental measurement and system related data from within the habitat. The system further includes a central thermal recovery unit in signal communication with the at least one controller and the at least one sensor. The central thermal recovery unit is configured for determining an operating instruction based on the at least one environmental measurement and system related data received from the at least one sensor and/or a third party database or interface, and transmitting the operating instruction to the at least one controller.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 14/029,011 filed Sep. 17, 2013 which is a continuation of U.S.patent application Ser. No. 13/753,585 filed Jan. 30, 2013, thedisclosures of which applications are incorporated herein by referencein their entirety.

FIELD OF THE INVENTION

The disclosed embodiment relates generally to the field of airconditioning and heating systems; more particularly, it concerns asystem for efficiently combusting fossil fuels for heating a space.

BACKGROUND

The conventional methodology used in utilizing fossil fuels for heatinghabitable spaces in commercial, industrial and residential buildings orstructures is firing the fuel in a controlled heating chamber or heatexchanger. The heat created by the burning fuel is drawn away by air orwater flowing around the outside of the heat exchanger. This can beaccomplished by blower fans or pumps. The heat is transferred into thesurrounding air or water, heating the conditioned space. The waste oremissions from the combustion reaction is allowed to flow outdoorsusually utilizing flue piping to a chimney or stack. The efficiency ofthe furnace or boiler is calculated by the amount of heat which can beextracted from the heat exchanger and utilized to heat the conditionedspace and the percentage of heat and by-products permitted to escapethrough the flue to be vented outside. This rating or efficiencyquantification is placed on the furnace or boiler to depict howefficient it will be.

Releasing carbon and heat saturated emissions into the atmospherecontribute to environmental problems, such as global warming. Not onlydoes carbon monoxide and carbon dioxide add to blanketing the release ofheat into space, discharging heat through flue gas emissions adds tothis issue by heat pollution. Just an average low to medium efficientresidential natural gas, LPG or oil furnace can emit about a halfmillion BTU's of heat waste into the atmosphere each day. Commercial andindustrial units can discharge hundreds of millions, and occasionallybillions, of BTU's per unit per day. In addition, these common andconventional methods of discharging the flue gas into the atmosphere arewasteful and inefficient.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and other features of the disclosed embodiment areexplained in the following description, taken in connection with theaccompanying drawings, wherein:

FIG. 1 is a schematic illustration of heat recovery assembly inaccordance with aspects of the disclosed embodiment.

FIG. 1A is a schematic illustration of a portion of a heat recoveryassembly in accordance with aspects of the disclosed embodiment.

FIG. 1B is a schematic illustration of a portion of a heat recoveryassembly in accordance with aspects of the disclosed embodiment.

FIG. 1C is a schematic illustration of a portion of a heat recoveryassembly in accordance with aspects of the disclosed embodiment.

FIG. 1D is a schematic illustration of a portion of a heat recoveryassembly in accordance with aspects of the disclosed embodiment.

FIG. 2 is a schematic illustration of heat recover assembly inaccordance with aspects of the disclosed embodiment.

FIG. 3 is a schematic illustration of the functionality of aspects ofthe heat recovery assembly of FIGS. 1 and 2.

FIG. 4 is a schematic illustration of a heat exchange process utilizedin aspects of the heat recovery assembly of FIGS. 1 and 2.

FIG. 5 is a schematic illustration of a heat recovery system inaccordance with aspects of the disclosed embodiment.

FIG. 5A is a schematic illustration of a heat recovery system inaccordance with aspects of the disclosed embodiment.

FIG. 6 is a schematic illustration of a heat recovery system utilizing aheat recovery ventilator assembly in accordance with aspects of thedisclosed embodiment.

FIG. 7 is a schematic illustration of a wiring diagram in accordancewith aspects of the heat recovery system illustrated in FIGS. 5 and 5A.

FIG. 8A is a perspective view of a heat recovery system in accordancewith aspects of the disclosed embodiment.

FIG. 8B is a perspective view of a heat recover system in accordancewith aspects of the disclosed embodiment.

FIG. 9 a perspective view of a heat recovery system in accordance withaspects of the disclosed embodiment.

FIG. 10 is a schematic illustration of a cut-away view in accordanceaspects of be heat recovery system illustrated in FIG. 9.

FIG. 10A is a schematic illustrate on of away view in accordance withaspects of the heat recovery system illustrated in FIG. 9.

FIG. 11 is a schematic illustration of a heat recovery system inaccordance with aspects the disclosed embodiment.

FIG. 12 is a schematic illustration of a heat recovery system inaccordance with aspects of the disclosed embodiment.

FIG. 13 is a schematic illustration of a heat recovery system inaccordance with aspects of the disclosed embodiment.

FIGS. 14A-14F are schematic illustrations of a portion of a heatrecovery system in accordance with aspects of the disclosed embodiment

FIG. 15 is a schematic illustration of a heat recovery system inaccordance with aspects of the disclosed embodiment.

FIG. 16 is a schematic illustration of a heat recovery system inaccordance with aspects of the disclosed embodiment.

FIG. 17 is a schematic illustration of a portion of a heat recoverysystem in accordance with aspects of the disclosed embodiment.

FIGS. 18A-18C are a flow diagram for operation of a heat recovery systemin accordance with aspects of the disclosed embodiment.

FIG. 19 is a block diagram of a heat recovery system employing a centralthermal recovery unit.

FIG. 20 is a block diagram illustrating the central thermal recoveryunit of FIG. 19.

FIG. 21 is system diagram illustrating a heat recovery system employinga central thermal recovery unit.

FIGS. 22-23 are example user interfaces for receiving system relatedinformation.

FIGS. 24-26 are example system operating reports showing systemoperation parameter and analysis.

Like reference numerals refer to like parts throughout the several viewsof the drawings.

DETAILED DESCRIPTION OF THE DISCLOSED EMBODIMENT

As illustrated in the accompanying drawings, the aspects of thedisclosed embodiment are directed to a heat and energy recovery assemblyand system, in addition to methods of using the same. The heat andenergy recovery assembly and system in accordance with aspects of thedisclosed embodiment may be adapted for use with any suitable heatingunit such as in a furnace of an HVAC system, boiler system or any othersystem where heat energy from fuel combustion is utilized for heatingair spaces or other fluid medium. Although the aspects of the disclosedembodiment will be described with reference to the drawings, it shouldbe understood that the aspects of the disclosed embodiment can beembodied in many forms. In addition, any suitable size, shape or type ofelements or materials could be used.

Ire one aspect of the disclosed embodiment, a heat recoveryassembly/system 100 is provided, as illustrated in FIG. 1 which whencombined with a heating furnace 2000 in a heat recovery system 200 (seefor exemplary purposes only FIGS. 5 and 5A) delivers heat to an area orhabitat to be heated such that the heat recovery assembly 100 capturesand delivers heat from heated air that is circulated in the habitat,exhaust gas from the furnace 2000 and heat stored in the thermal massthat is the furnace assembly. As may be realized, the furnace 2000includes a controller 1311F that includes any suitable non-transitoryprogram code for effecting a heating cycle of the furnace 2000. Forexample, every time a thermostat, such as thermostat TSH, calls forheat, the controller 1311F of the furnace 2000 detects the call for heat(e.g. receives a signal from the thermostat TSH) and starts the furnaceheating cycle by first activating the furnace exhaust induction fanmotor. Once the controller 1311F confirms proper exhaust pressure ispresent, the furnace igniter is turned on and verified by the controlsystem. The furnace fuel valve FV opens, the furnace burners FBRN lightand heat creation begins. As an example, on a 100,000 btuh furnace, heatis created at a rate about 28 btus per second. The motor of the furnaceblower FIB cannot be turned on until the furnace heat exchanger FHX ishot enough to deliver warm air to a habitat to be heated. For a period(e.g., a latent heating period) of about 1 to about 2 minutes on mostfurnaces, while the heat exchanger is warming up, there is no airblowing along the outside of the furnace heat exchanger FXH. If thefurnace heat exchanger FHX warm up or latent cycle is about 1 minutelong, for exemplary purposes only, approximately 1500 btus of fuel isconsumed and that energy is either stored in the thermal mass of thefurnace heat exchanger FHX or exhausted out of the furnace exhaust 2100.When the motor of the furnace blower FIB is finally turned on heat istransferred from the furnace heat exchanger FHX to, for example the airfrom the return plenum 1300 (e.g. the source heating period). When theheat call from the thermostat TSH is satisfied, the furnace burners FBRNare turned off however, according to the furnace programming the furnaceblower continues to run for about 2 to about 4 minutes deliveringadditional heat to the house (e.g. the residual heating period). As maybe realized, the about 1 to about 2 minute warm up period and the about2 minute to about 4 minute cool down period represents about 3 to about6 minutes (5-10% of an hour) of furnace operation at lower efficiencythan the rated steady state efficiency of the furnace 2000 so, forexample, is a furnace 2000 is cycled on and off 3 to 5 times an hour(where, e.g., each cycle corresponds to a heat call from thethermostat), then about 15% to about 50% of the time the furnace 2000 isrunning, the furnace is running below its rated efficiency.

The heat recovery assembly/system 100 of the aspects of the disclosedembodiment include a multiple stage heat exchange system 120EX that isconfigured to recover heat lost during, for example, the warm up andcool down periods of the furnace. Further, in a conventional system thefurnace is in an on state (e.g. burners FBRN lit) for 100% of the timeduring the heat call. The aspects of the disclosed embodiment describedherein operate to discontinuously run the furnace 2000 in short burstsduring a heat call so that the furnace 2000 is cycled on and off toachieve a higher efficiency by creating the start up and cool downfurnace cycles/periods as frequently as, for example, 20 times per hour(based on, for example, a 1 hour long heat call) where, for example,during each 180 second cycle the burners FBRN are on for approximately100 seconds and off for about 80 seconds so that heat isextracted/recovered during the start up and cool down periods, asdescribed herein, to increase furnace efficiency and decrease fuelconsumption. As will be described herein, during the furnace off timesat least one stage of the multiple stage heat exchange system 120EXextracts residual heat from the furnace 2000 to balance a heat exchangeto the supply air for heating the habitat (e.g. the multiple stage heatexchange system 120EX operates as a thermal balance to maintain atemperature of the supply air above a predetermined set point forheating the habitat during periods of the heat call where the furnace2000 is turned off).

In one aspect, the assembly 100 includes a heat recovery chamber 110which comprises a cooling intake 112 and an exhaust gas or emissionsintake 114 for receiving exhaust gas and waste products emitted as aresult of fuel combustion. It should be understood that while the heatrecovery chamber 110 is illustrated in the figures as being cuboid inshape in other aspects the heat recovery chamber 110 has any suitableshape and/or configuration. For example, in other aspects, the heatrecovery chamber 110 is a cylindrical drum, a pyramid or any othersuitable shape. In one aspect, referring to FIG. 11, a portion of theheat recovery chamber 110B, such as a mixing portion 110C, may beintegral with, for example, the exhaust gas intake 114 or any othersuitable ducting so that exhaust from a furnace 2000 or boiler andcooling gas from cooling intake 112 is at least partially mixed withinthe ducting prior to contacting a heat exchanger, such as a firstmultiple stage heat exchanger 118 (which includes one or more heatexchange elements 116A, 116B), of the multiple stage heat exchangesystem 120EX, for recovering heat described below. In one aspect theheat recovery chamber 110 is an insulated chamber while, in otheraspects the heat recovery chamber 110 is uninsulated. The heat recoverychamber 110 is made from any suitable material such any suitablenon-metallic material, plastics, PVC, ceramics, metals or alloys. In oneaspect the heat recovery chamber 110 is made of stainless steel and/ortitanium alloy.

The assembly 100 further includes a portion of the multiple stage heatexchange system 120EX such as the first multiple stage heat exchanger orabsorber 116 (referred to herein as heat exchanger 116) noted above. Inone aspect the first heat exchanger 116 is disposed within the heatrecovery chamber 110 while in other aspects the first heat exchanger 116is communicably coupled to the heat recovery chamber 110 in any suitablemanner. For example, as described above with respect to FIG. 11, apre-mixing/mixing chamber 110C, in one aspect, is integrated into anysuitable ducting so that the exhaust gas and cooling gas are mixed (e.g.pre-mixed) prior contacting the first heat exchanger 116. In thisaspect, illustrated in FIG. 11, the first heat exchanger 116 is disposedin a heat recovery chamber 110B that may be substantially similar toheat recovery chamber 110 however, the exhaust gas, and cooling gas maybe substantially combined prior to entering the heat recovery chamber110B. Also referring to FIG. 12 the heat recovery chamber 110constitutes a premix chamber 110A in which cooling gas from the coolingintake 112 and exhaust from the exhaust gas intake 114 mix or otherwisecombine. The mixed gas flows into the heat exchange chamber 110B inwhich the first heat exchanger 116 is disposed. The first heat exchanger116 includes one or more heat exchange elements 116A, 116B structuredfor contacting a mixture made up of cooling gas introduced via thecooling intake 112 and exhaust gas (e.g. made up of carbon emissions)introduced via the exhaust gas intake 114. In one aspect heat exchangeelement 116A is larger than heat exchange element 116B while in otheraspects the one or more heat exchange elements 116A, 116B have anysuitable size relationship with each other. In one aspect, one or morecoil sensors CS1, CS2 are in contact with one or more of the heatexchange elements 116A, 1116B of the first heat exchanger 116 to relayany problems with the functionality (such as, for example, icing orfrosting) of the one or more heat exchange elements 116A, 116B of thefirst heat exchanger 116 to a central logic board (discussed laterherein) or any other suitable controller, such as controller 1311 (FIGS.1 and 13) which is connected to the furnace controller 1311F in anysuitable manner and is configured to operate the heat, recovery assemblysystem 100 as described herein. In one aspect, the one or more heatexchange elements 116A, 116B of the first heat exchanger 116 are madefrom any suitable material, such as a metallic or non-metallic materialthat allows for an exchange of heat. In one aspect the one or more heatexchange elements 116A, 116B of the first heat exchanger 116 areconstructed of, for example metals and/or alloys, such as but notlimited to, copper, aluminum and the like. In one aspect, the one ormore heat exchange elements 116A, 116B of the first heat exchanger 116is/are heat exchange coil(s) such as an evaporative coil(s) and/or useany suitable coolant or refrigerant such as a single phase coolant.

It should be understood that while the first heat exchanger 116 isillustrated as having two heat exchange elements 116A, 116B in FIG. 1,in other aspects the first heat exchanger 116 has more (see e.g. FIG.1A) or less (see e.g. FIG. 10) than two heat exchange elements. Forexample, referring to FIG. 1A the heat recovery chamber 110 includes afirst heat exchanger 116 that includes four heat exchange elements 116A,116B, 116C, 116D disposed in sets of two (e.g. each set having a largeand small heat exchange element or any suitably sized heat exchangeelements as described above) having an opposing relationship so thatgases passing through the heat recovery chamber 110 pass through one ofthe sets of heat exchange elements 116A, 116B, 116C, 116D. As may berealized, the recovery chamber 110, in one aspect, includes sub-chambers110C1, 110C2. As can be seen in FIG. 1A the furnace exhaust and coolinggas are introduced into sub-chamber 110C1, flow through sub-chamber110C1 and into sub-chamber 110C2 where the heat exchange elements 116A,116B, 116C, 116D (e.g., of the stage one and stage two fluid circuits120, 120A as described below) are located. Also referring to FIG. 1D, inone aspect the stage two fluid circuit 120A includes one heat exchangeelement 116B located in sub-chamber 110C1 while the heat exchangeelements of the stage one fluid circuit 120 are located in thesub-chamber 110C2. It should also be understood that the one or moreheat exchange elements 116A, 116B, 116C, 116D have any suitablearrangement within the heat recovery chamber 110. As may also berealized, each heat exchange element has, is part of a fluid circuitthat is independently operable from other fluid circuits (e.g. each heatexchange element forms part of a separate stage of the multiple stageheat exchanger).

The cooling intake 112 has any suitable shape and/or configuration andin one aspect structured as a single intake or in other aspects asmultiple intakes. The cooling intake(s) 112 are configured to introduceone or more of indoor air or cooling gas (which is discharged from theheat recovery chamber 110 and recirculated) into the heat recoverychamber 110. In one aspect the cooling intake 112 is a closed loopextending from the chamber exhaust 118 to the heat recovery chamber 110as described below. As will also be described below, in one aspect thecooling intake includes an active or passive orifice ORIF (which in oneaspect includes a valve 112V—see FIGS. 1A and 13) that is opened andclosed to direct any predetermined volume of cooling gas back to therecovery chamber 110. In one aspect about 50% of the gas exiting therecovery chamber is recirculated back to the recovery chamber 110 whilein other aspects any suitable volume of gas is recirculated. In oneaspect of the disclosed embodiment any suitable fans or blowers areprovided in any suitable manner to generate a balanced pressureenvironment within the heat recovery chamber 110 as described herein. Inanother aspect one or more of the cooling intake(s) 112 are communicablyconnected to a pressure regulator inducer blower (also referred toherein as a fan) 140 (see e.g. FIG. 4) that may be part of any suitablepressure equalization system to assist in moving the gas inside the heatrecovery chamber 110 out of the heat recovery chamber where a portion ofthe exhaust is directed out of the chamber exhaust 118 and a portion ofthe exhaust is directed to the cooling intake 112. In one aspect theinducer blower 140 is located on the exhaust side of the heat recoverychamber 110 as will described below while in other aspects the inducerblower is located at any suitable location. In one aspect the fan 140includes a variable speed motor that is controlled by any suitablesensors in communication with an interior of the heat recovery chamber110 and configured to detect proper temperature and/or humidity and/orpressure of the gas inside the heat recovery chamber 110.

In one aspect the one or more heat exchange elements 116A 116B of thefirst heat exchanger 116 are interconnected in any suitable manner to arespective stage of a multi-stage fluid circuit system. For example,heat exchange element is connected to stage one fluid circuit 120 andheat exchange element is connected to stage two fluid circuit 120A (e.g.each heat exchange element is interconnected with a fluid circuit thatis separate and distinct (e.g. independently operable) from other fluidcircuits of other heat exchange elements where each fluid circuit hasits own compressor 150, 150A) where the fluid circuits 120, 120A are anysuitable fluid circuits. In other aspects the one or more heat exchangeelements 116A, 116B are interconnected to a common fluid circuit suchthat coolant is shared between the one or more heat exchange elements116A, 116B. The respective fluid circuit(s) 120, 120A include anysuitable conduit 122, 122A for conveying fluid within the respectivefluid circuit 120, 120A. The multiple stage heat exchanger system 120EXof the assembly 100 includes a second multiple stage heat exchanger oremitter 130 (e.g. a heat extraction exchanger) including one or moreheat exchange elements 130A, 130B disposed exterior to the heat recoverychamber 110 such that each heat exchanger 130A, 130B of the secondmultiple stage heat exchanger 130 (referred to herein as heat exchanger130) is in fluid communication with a respective fluid circuit 120, 120Avia the respective conduit 122, 122A. In one aspect, heat exchangeelement 130A of the second heat exchanger 130 and heat exchange element116A of the first heat exchanger 116 are communicably interconnected viathe conduit 122 of the fluid circuit 120 such that the heat exchangeelement 116A of the first heat exchanger 116 contacts or otherwiseinterfaces with (e.g. within the heat recovery chamber 110 or in anyother suitable manner as described herein) the mixture made up ofcooling gas introduced via the cooling intake 112 and exhaust gasintroduced via the exhaust gas intake 114, while the heat exchangeelement 130A of the second heat exchanger 130 contacts or otherwiseinterfaces in any suitable manner with air to be heated, outside of theheat recovery chamber 110. Similarly, heat exchange element 130B of thesecond heat exchanger 130 and heat exchange element 116B of the firstheat exchanger 116 are communicably interconnected via the conduit 122Aof the fluid circuit 120A such that the heat exchange element 116B ofthe first heat exchanger 116 contacts or otherwise interfaces with (e.g.within the heat recovery chamber 110 or in any other suitable manner asdescribed herein) the mixture made up of cooling gas introduced via thecooling intake 112 and exhaust gas introduced via the exhaust gas intake114, while the heat exchange element 130B of the second heat exchanger130 contacts or otherwise interfaces in any suitable manner with air tobe heated, outside of the heat recovery chamber 110. In other aspects,the heat exchange elements of the first and second heat exchangers 116,130 are interconnected in any suitable manner. It should be realized,that while a two stage heat exchange system is illustrated and describedin other aspects the heat exchange system has any suitable number ofstages, such as more or less than two stages. As may also be realized,the heat exchange element 116A, fluid circuit 120 and heat exchangeelement 130A constitute the first stage of the multiple stage heatexchange system 120EX and the heat exchange element 116B, fluid circuit120A and heat exchange element 130B constitute the second stage of themultiple stage heat exchange system 120EX.

Referring to FIGS. 1B and 1C the one or more heat exchange elements130A, 130B of the second heat exchanger 130 are, in one aspect,condenser coils having any suitable size(s), shapes and/or arrangement.In one aspect the heat exchange element 130A includes two heat exchangeelements 130A1, 130A2 coupled together in series to form a slabcondenser coil. In one aspect, the two heat exchange elements 130A1,130A2 of the heat exchange element 130A include vertical pipes andhorizontal fins. In other aspects the heat exchange element is a singleheat exchange element having horizontal pipe and vertical fins orvortical pipe and horizontal fins. The heat exchange element 130B issmaller than heat exchange element 130A and in one aspect includeshorizontal pipes and vertical fins or vertical pipes and horizontalfins. As may be realized, the pipe and fin arrangement of the one ormore heat exchange elements 130A, 130B is such that the pipes and finsof heat exchange element 130A intersect the pipes and fins of heatexchange element 130B (e.g. where heat exchange element 130A includeshorizontal pipes and vertical fins the heat exchange element includesvertical pipes and horizontal fins) to facilitate a maximized heattransfer through the one or more heat exchange elements 130A, 130B.

In one aspect the heat recovery chamber 110 includes exhaust anddrainage components. An exhaust 118 for discharging the exhaust gas(e.g. a portion of which is recirculated as cooling gas) after heatexchange occurs is configured or otherwise structured to interconnect,for example, the heat recovery chamber 110 to the outside environmentand/or to cooling intake 112 for recirculating at least a portion of theexhaust gas (e.g. the cooling gas) back into the heat recovery chamber110 as will be described in greater detail below. The heat recoveryassembly/system 100 when combined with, for example, a furnace 2000having about an 80% efficiency produces exhaust gas temperatures (Asdescribed herein) that enable the exhaust duct (e.g. exhaust 118) to beformed of PVC rather than metal of ceramic (e.g. effects the coupling ofa PVC exhaust duct to the combination of the heat recoveryassembly/system 100 and the furnace 2000). In one aspect, the exhaust118 is a single two-inch pvc vent pipe while in other aspects theexhaust 118 has any suitable size and is constructed of any suitablematerial such as composites, metals, etc. In one aspect a drain 111 isconnected to the heat recovery chamber 110 and is configured to carrycondensate water WD that may include particulates, ash and/or soot outof the heat recovery chamber 110. In one aspect for example, a mister113 is included in the heat recovery chamber 110, however in otheraspects the mister 113 is not provided. The mister 113 is configured tosaturate the gas within the heat recovery chamber 110 with moisture andto help capture and remove particulates, ash and/or soot from theexhaust gases in any suitable manner, such as by the particulates, ashand/or soot becoming saturated with water from the flash heat steamfrom, for example, the super heated oil combustion exhaust gas andfalling to the bottom of the chamber to be discharged through the drain111. In other aspects, the mister 113 may not be provided such that thecondensate water WD is formed from moisture in the exhaust gas and/orcooling gas introduced through cooling intake 112 and helps capture andremove particulates, ash and/or soot from the exhaust gases. In oneaspect a filter or other mechanical separation unit is provided toremove the particulates, ash and/or soot from the condensate water WDdischarged through the drain 111. Where the mister 113 is provided themister 113 is, in one aspect, connected to a pressurized water tube toprovide water to the heat recovery chamber 110 to raise the dew pointwithin the heat recovery chamber 110 to raise the heat transferpotential.

The aspects of the disclosed embodiment illustrated in FIG. 1 aredesigned for use when the exhaust gas input through the exhaust gasintake 114 originates from the burning of cleaner burning propane orother natural gases, such as but not limited to, a natural gas-burningfurnace component of a heating, ventilation and air conditioning (HVAC)unit. However, it should be understood by those skilled in the art thatthe assembly 100 could be utilized in other situations where thesurrounding air is to be heating by fossil fuel combustion.

FIG. 2 illustrates an aspect of the disclosed embodiment of the assembly100 that may be used when the exhaust gas input to the heat recoverychamber 110 through the exhaust gas intake 114 originates from anoil-burning furnace. As may be realized, this aspect of the disclosedembodiment may also be used when the exhaust gas input to the heatrecovery chamber 110 through the exhaust gas intake 114 originates fromburning of natural gas as well. The components and configuration of thisaspect of the disclosed embodiment are generally the same as in FIG. 1;however, additional aspects are included for capturing the heat that isstored in the condensate water WD that may accumulate within, such as atthe bottom, of the heat recovery chamber 110. While the capturing ofheat stored in the condensate water WD is described with respect to theheat recovery chamber 110 in FIG. 2 it should be understood that, inother aspect, capturing heat stored in condensate water WD in the heatexchange chamber 110B (see e.g. FIGS. 11 and 12) is provided in a mannersubstantially similar to that described herein. In other aspects heatcaptured in the condensate water WD may be recovered from the heatrecovery chamber 110, 110B. The aspects of the disclosed embodimentillustrated in FIG. 2 include a third heat exchanger 117 in fluidcommunication with one or more of the first heat exchanger 116 and thesecond heat exchanger 130 via a second conduit 124 for absorbing theexcess heat stored in the water as it accumulates from the condensatewater WD produced within the heat recovery chamber. Since the secondconduit 124 is in communication with one or more of the first heatexchanger 116 and the second heat exchanger 130, the third heatexchanger 117 may be further in fluid communication with one or more ofthe fluid circuits 120, 120A as a whole. The drain 111 in FIG. 2 isshown, for exemplary purposes, to be structured such that condensatewater WD and ash/soot within the condensate water WD does not drain fromthe heat recovery chamber 110 until the water rises to a certain level,WL. This allows the third heat exchanger 117 to remain underneath thesurface of the condensate water WD as it absorbs the excess heat energystored in the condensate water WD so that very little, or none, of theheat energy remains unabsorbed in the entire process (e.g. substantiallyall heat energy is extracted from the condensate water WD).

During operation of the assembly and/or system of the disclosedembodiment, hot exhaust gases and combustion products (carbon monoxide,carbon dioxide, H20, etc.) are exhausted into the heat recovery chamber110. In one aspect, one or more of indoor air and cooling gas isintroduced into the heat recovery chamber 110 in any suitable manner tomix with the hot exhaust gas. A large, cubic footprint of gas issaturated and heated as a result of the mixing. This mixture flowsacross one or more heat exchange elements 116A, 116B of the first heatexchanger 116 while the dew point rises, holding water and heat(saturation). The heat is extracted from the mixture via the one or moreheat exchange elements 116A, 116B of the first heat exchanger 116 (andthird heat exchanger 117 when provided) and transferred to a respectiveone of the one or more heat exchange elements 130A, 130B of the secondheat exchanger 130 such that heat transfer occurs at the one or moreheat exchange elements 130A, 130B of the second heat exchanger 130 toheat, for example, indoor air or any other suitable medium. Cooler, drygas from the heat recovery chamber 110 is exported outdoors in anysuitable manner, such as through any suitable chimney or exhaust flue,with a reduced heat, moisture and carbon content. In addition, asdescribed herein, at least a portion of the cooler, dry gas from theheat recovery chamber 110 is recirculated (e.g. as cooling gas) backinto the heat recovery chamber 110. This process allows heat energy tobe pulled from the gas introduced into the heat recovery chamber suchthat it is compounded with the heat energy already being produced by thefossil fuel combustion process. This provides the assembly and systemdescribed herein in accordance with the aspects of the disclosedembodiment the potential to achieve a higher efficiency of fuel burn.

By way of example and referring to FIG. 3, aspects of the disclosedembodiment of the heat recovery assembly/system 100 are illustrated withrespect to an exemplary 80% annual fuel utilization efficiency (AFUE)furnace rated at 100,000 input/80,000 output. Hot, moist exhaust, gasesare extracted from the furnace at approximately 375° F. withapproximately 90% plus humidity at approximately 55CFM. In other aspectsthe exhaust gases have any suitable temperature and humidity and areextracted at any suitable rate. The hot, water-saturated, exhaust gascarries a large heat potential (of e.g. at least 20,000 British ThermalUnits per Hour (BTUH)). In addition to heat energy, the water-saturationof the exhaust gas (e.g. misting may increase this water-saturationwhere provided) includes high levels of potential energy for extraction.These exhaust gases are mixed with dry, cool gas (e.g. the cooling gas)of equal cubic feet per minute (CFM) using, for example, pressureregulation in the heat recovery chamber 110. In one aspect the cool drygas (e.g. cooling gas) is obtained from the discharge 118 of the heatrecovery chamber 110 (as shown in, for example, FIG. 4A) where afterheat extraction at least a portion of the discharge exhaust gas isreturned to the heat recovery chamber 110 under the influence of a fan140. Referring also to FIG. 4 the pressure regulation of the heatrecovery assembly 100 effected by a balanced pressure system where thefan 140 is placed downstream of the heat recovery chamber 110 so as todraw or suck the gasses out of the heat recovery chamber 110. In oneaspect, the fan 140 is sized so as to be substantially equal totwo-times the cfm of the furnace inducer fan motor so that thedischarged exhaust gas from the heat recovery chamber is split so thatsubstantially half the discharged exhaust gas (e.g. cool dry gas orcooling gas) is returned to the heat recovery chamber to cool and bemixed with the gases from the furnace 2000 that enter the heat recoverychamber through gas intake 114. In other aspects, the fan 140B is sizedto recover any suitable portion of the discharged exhaust gas from theheat recovery chamber for mixing with and cooling the gases from thefurnace 2000 input to the heat recovery chamber 110 through gas intake114. As may be realized, mixing the gases from the furnace with thecooling gas from the heat recovery chamber 110 substantially eliminatesany influence of fluctuating outdoor temperatures on the heat recoveryassembly 100 and substantially isolates the furnace from outdoorpressure/wind influences. As may be realized, the fan(s) 140 controlledin any suitable manner, such as by controller 1311 and/or by a rheostatto allow balancing of gas flow volume and velocity through the heatrecovery assembly 100.

Within the teat recovery chamber 110 under controlled conditions, in oneaspect, the cooling gas, described herein, is saturated by the mistedwater within the exhaust gas, resulting in an increase in the dew pointwhile in other aspects the cooling gas is not misted. The heat energyreleased in the exhaust gas (which may have a temperature ofapproximately 375° F. or any other suitable temperature) mixes with thecooling gas, resulting in a mean temperature of approximately 160° F.(or any other suitable temperature). The combined gases include oxygen(O₂) assisting in the heat transfer process. The combined gases are awarm (about 160° F. or other suitable temperature), high dew point gashaving, for example, a high-energy potential for high efficiency heatand energy extraction.

This combined gas mixture passes over one or more of the heat exchangeelements 116A, 116B of the first heat exchanger 116. The fluid, e.g.refrigerant, in the one or more heat exchange elements 116A, 116B of thefirst heat exchanger 116 is under controlled pressurized conditions andis able to extract a large amount of heat energy from the combined gasmixture and transfer the heat energy to the a respective one of the oneor more heat exchange elements 130A, 130B of the second heat exchanger130 via the respective fluid circuit 120, 120A such that the transferredheat energy warms the indoor air as the indoor air flows over the one ormore heat exchange elements 130A, 130B of the second heat exchanger 130.The flow of refrigerant in the fluid circuit 120, 120A between each ofthe components of the assembly is illustrated by arrows in FIG. 3. Theexhaust gas discharged from the heat recovery chamber following thecontrolled and regulated mixing within the heat recovery chamber 110 maybe dry, cool exhaust gas. For exemplary purposes, the average dischargedexhaust gas from the heat recovery chamber 110 has a temperature ofabout 42° F. to about 49° F., a humidity of about 10%, and about a0.05-0.00 PPM CO (carbon monoxide) content. In one aspect one or moresuitable thermostat or temperature sensor TS is mounted on the furnacesupply plenum or duct 1301 (and/or on the furnace return plenum 1300)and is positioned outside of any thermal influence of the heat thatradiates from the thermal mass of the one or more heat exchange elements130A, 130B. The thermostat TS is connected to the controller 1311 in anymanner so as to effect operation of the heat recovery system 100 asdescribed herein.

Still referring to FIG. 3 and also to FIGS. 18A-18C, an operation of theheat recovery assembly and systems described herein is described ingreater detail. In one aspect the controller 1311 is in a monitoringstate that monitors a state of the furnace 2000 and one or morethermostats TSH that control the heating in one or more heating zones ofa building or other area to be heated (FIG. 18A, Block 9000). When theone or more thermostats TSH detect a temperature that is less than apredetermined set temperature of the thermostat TSH the thermostat sendsany suitable signal to the controller 1311. The controller 1311 detectsthe signal and the heat call embodied in that signal (FIG. 18, Block9001). The controller 1311 is, in one aspect, configured to determine ifthe heat call is a false alarm. Where the heat call is a false alarm thecontroller 1311 returns to the monitoring state (FIG. 18, Block 9002).Where the heat call is valid the controller 1311 forwards the heat callto the furnace controller 1311F to effect turning the furnace 2000 andthe fan 140 on (FIG. 18A, Block 9003). The controller 1311 is alsoconfigured to determine if the heat call remains active (FIG. 18A, Block9005). In one aspect, the controller 1311 waits any suitablepredetermined time period before determining if the heat call remainsactive (FIG. 18A, Block 9004). If the heat call is no longer active thecontroller 1311 turns the furnace 2000 off (FIG. 18A, 9006) by sendingany suitable signal to the furnace controller 1311F and returns to themonitoring state (FIG. 18A, Block 9007). Where the heat call remainsactive the controller 1311 turns on compressor 150 (FIG. 18A, Block9008) and compressor 150A (FIG. 18A, Block 9009). In one aspect, thecontroller 1311 waits any suitable predetermined amount time periodbetween the starting of compressor 150 and the starting of compressor150A. The controller 1311 determines if the heat call remains active(FIG. 18A, Block 9010). Where the heat call is inactive the controller1311 turns the furnace 2000, the fan 150, 150A and the compressors 150,150A off (FIG. 18A, Block 9011) and returns to the monitoring state(FIG. 18A, Block 9012). Where the heat call remains active controllerproceeds to an active state (FIG. 18A, Block 9014). In one aspect thecontroller waits any suitable predetermined time period beforeproceeding to the active state (FIG. 18A, Block 9013).

In the active state the controller 1311 monitors whether the thermostatTSH temperature is satisfied (FIG. 18B, Block 9015). Where thethermostat TSH temperature is satisfied the controller 1311 turns thecompressors 150, 150A, the fan 140 and the furnace off (FIG. 18B, Blocks9016, 9018) and returns to the monitoring state 9019. In one aspect thecontroller 1311 waits any suitable time period before turning the fan140 off (FIG. 18B, Block 9017). If the thermostat TSH temperature is notsatisfied the controller determines, from any suitable temperaturesensors whether the one or more heat exchange elements, such as heatexchange elements 116A, 116B, require defrosting (FIG. 18B, Block 9020).

If one or more heat exchangers require defrosting the controller 1311determines if the call for defrosting is valid such that if the call fordefrosting is not valid the controller 1311 returns to the active state(FIG. 18B, Block 9021). Where the call for defrosting is valid thecontroller 1311 turns the compressor(s) 150, 150A off (FIG. 18B, Block9022), waits a predetermined amount of time suitable for defrosting(e.g. a defrost cycle) the one or more heat exchange elements 116A, 116B(FIG. 188, Block 9023) and returns to the monitoring state (FIG. 18B,Block 9024). If the thermostat heat call is satisfied during the defrostwaiting period the defrost cycle ends and the controller 1311 returns tothe monitoring state (FIG. 18B, Block 9025). Where there is no call fordefrosting the one or more heat exchange elements 116A, 116B thecontroller 1311 determines if the furnace 2000 has failed (FIG. 18B,Block 9026).

Where the controller receives a furnace fail call from, for example, anysuitable sensors connected to the furnace, the controller 1311determines if the furnace fall call is valid and if the furnace failcall is not valid the controller 1311 returns to the active state (FIG.18B, Block 9027). If the controller 1311 determines that the furnacefail call is valid the controller 1311 turns the compressor(s) 150, 150Aand the furnace 2000 off (FIG. 18B, Block 9028) and waits apredetermined period of time (FIG. 18B, Block 9029) before turning thefan 140 off (FIG. 18B, Block 9030) and returning to the monitoring state(FIG. 18B, Block 9031). Where there is no furnace fail call thecontroller determines if the heat recovery assembly 100 has failed (e.g.the controller receives a heat recovery assembly fail call from anysuitable sensors connected to the heat recovery assembly 100) (FIG. 18B,Block 9032).

Where the controller receives a heat recovery assembly fail call thecontroller 1311 determines if the heat recovery assembly fail call isvalid and if the heat recovery assembly fail call is not valid thecontroller 1311 returns to the active state (FIG. 18B, Block 9033). Ifthe controller 1311 determines that the heat recovery assembly fail callis valid the controller 1311 turns the compressor(s) 150, 150A and thefurnace 2000 off and turns the fan 140 on (FIG. 18B, Block 9034). Thecontroller effects any suitable aural and/or visual alert indicating areset of the heat recovery assembly 100 is needed (FIG. 18B, Block 9035)and when the heat recovery assembly 100 is reset the controller 1311returns to the monitoring state (FIG. 18B, Block 9036). If there is noheat recovery assembly fail call the controller 1311 enters, a heatcycle mode (FIG. 18B Block 9037).

As described above, a temperature sensor TS is mounted on or within thefurnace supply plenum or duct 1301 of the furnace 2000. When the furnace2000 is burning gas (e.g. is turned on the heat recovery assembly 100 isextracting heat from the furnace exhaust gas and preheating the air inthe return plenum 1300 so that hot air is produced at elevatedtemperatures compared to the furnace 2000 running by itself. The sensorTS is monitored by the controller 1311 (FIG. 18C, Block 9038) and is setto trigger or otherwise send a signal to the controller at any suitablepredetermined high temperature threshold or set point, such as about130° F. (in other aspects the high temperature threshold is more or lessthan 130° F.) When the controller 1311 receives a signal from thetemperature sensor TS that the high temperature threshold is reached thecontroller interrupts the thermostat TSH heat call which closes thefurnace fuel valve FV and shuts off the burners FBRN (e.g. turns thefurnace off however, the blower FIB remains running for a predeterminedperiod of time per furnace programming as described herein) and turnsthe stage 2 compressor 150A off (FIG. 18C, Block 9039). In this aspect,the heat recovery assembly 100 leverages the furnace programming (e.g.incorporates the embedded furnace controller 1311F that continues to runthe blower FIB for a predetermined period of time, as described above,after the burners FBRN are turned off) and continues to extract andtransfer heat from the residual heat from the furnace 2000 in thechamber 110 and into the supply air stream (e.g. the blower FIBcontinues to operate so that air moves over/through the heatexchanger(s) 130A, 130B, FH X while the heat being transferred from theheat exchanger 116A decreases). As may be realized, the temperaturesensor TS in the supply plenum 1301 is further configured to send asignal to the controller 1311 indicating a predetermined low temperaturethreshold or set point, such as about 100° F. (in other aspects the lowtemperature threshold is more or less than 100° . F). The controller1311 monitors the temperatures sensor TS for a low temperature thresholdsignal (FIG. 18C, Block 9040) and if the low temperature thresholdsignal is received by the controller 1311, the controller 1311reinstates the thermostat TSH heat call so that the furnace 2000 and thestage 2 compressor 150A are turned on (FIG. 18C, Block 9041) and theprocess returns to block 9038 so that the furnace is discontinuously runin short bursts so that the furnace is cycled between the on and offstates during the heat call. As may be realized, the low temperaturethreshold is such that the low temperature threshold is reached beforethe blower FIB turns off so that air is continually circulating throughthe furnace heat exchanger FHX for delivering heat to the supply airduring the heat call whether the burners FBRN are lit or off. In otheraspects, the controller 1311 includes any suitable programming forturning the burners FBRN back on prior to the blower FIB being turnedoff (e.g. if the low temperature threshold is not met or for any othersuitable reasons). If the low temperature threshold signal is notreceived the controller 1311 monitors the furnace blower timeout (e.g.the period of time the blower FIB operates after the burners FBRN areturned off) (FIG. 18C, Block 9040A). If a predetermined time periodprior (e.g. any suitable time period such as seconds before theexpiration of the timeout, a minute before the timeout, etc.) to thetimeout period expiring has not been reached (FIG. 18C, Block 9040B) thecontroller 1311 continues to monitor for the low temperature thresholdsignal. If the predetermined time period prior to the timeout periodexpiring has been reached (FIG. 18C, Block 9040B) the controller 1311reinstates the thermostat TSH heat call so that the furnace 2000 and thestage 2 compressor 150A are turned on (FIG. 18C, Block 9041) and theprocess returns to block 9038 so that the furnace is discontinuously runin short bursts so that the furnace is cycled between the on and offstates during the heat call.

If the thermostat TSH heat call is satisfied the controller 1311 returnsto the monitoring state and the furnace 2000, compressor(s) 150, 150Aand fan 140 are turned off (FIG. 18C, Block 9042). As may be realized,the monitoring of the temperature sensor TS in the supply plenum 1301effects a repeating on/off cycling of the furnace burners FBRN (e.g. thefurnace is cycled between being turned on and being turned off) untilthe thermostat TSH heat call is satisfied which shuts the furnace 2000and the heat recovery assembly 100 down until the next thermostat TSHheat call. In other words, the controller 1311 is coupled to thetemperature sensor TS having predetermined hi and low temperature setpoints and is configured or otherwise programmed so that in response tothe heat call from the thermostat TSH the furnace is repeatedly cycled(e.g. run discontinuously or turned on and off) when the controller 1311registers the temperature sensor TS signal corresponding to the hitemperature set point (e.g. the furnace is turned off) and the lowtemperature set point (e.g. the furnace is turned on).

The following is an exemplary table illustrating tests performed onvarious furnaces where the input/size is the btu rating of the furnacetested, cfm is the amount of air moved by the furnace tested, target isthe targeted btus from the heat recovery assembly/system 100 to be addedto the furnace heat output, the cycles per hour is the number of timesthe furnace tested was discontinuously run (e.g. turned on and off) overa one hour heat call, the average supply temperature (° F.) is theaverage temperature of the air passing through the return plenum 1300during both furnace on and off states/periods, the average returntemperature (° F.) is the average temperature of the air returning tothe return plenum 1300 during both furnace on and off states/periods,the average delta temperature (° F.) is the difference between theaverage supply temperature and the average return temperature, the addedbtus are the btus recovered by the heat recovery assembly/system 100described herein and the fuel btus is the amount of btus obtained fromburning fuel during furnace on states/periods, efficiency is the fuelconversion efficiency of the furnace with the heat recoveryassembly/system 100, variation is the difference between the target btusand the added btus, on second refers to the amount of firm the furnacewas in the on state during each cycle of the discontinuous furnaceoperation, off seconds refers to the amount of time the furnace was inthe off state during each cycle of the discontinuous furnace operation,therms is the amount of heat energy from fuel burned (e.g. the fuelbtus), latent refers to an amount of heat (btus) of e-strained water andrecovered by the heat recovery assembly/system 100 throughout theheating cycle, source is the amount of heat (btus) recovered by the heatrecovery assembly/system 100 during furnace operation, and residual isthe amount of heat (btus) recovered by the heat recovery assembly/system100 during furnace cool down periods.

Cycles Average Average Average Input/ per supply return delta Furnacesize Cfm Target hour temp temp temp 2 60000 1150 48000 13.90 120.3 64.855.5 1 88000 1210 70400 19.40 116.1 66.6 49.5 4 100000 1674 80000 23.50115.4 67.1 48.3 6 120000 1513 96000 29.00 124.9 67.7 57.2 5 140000 1500112000 23.00 140.5 71.6 68.9

Added Fuel On Off Furnace btus btus Efficiency Variation seconds seconds2 72122 35900 200.9% 24122  115 150 1 67695 35180 192.4% (2705) 110 85 491365 62720 145.7% 11365  95 55 6 97794 64910 150.7% 1794 65 50 5 11678673800 158.2% 4786 95 55

Furnace therms latent source residual 2 0.3590 2901 35900 33321 1 0.35182843 35180 29672 4 0.6272 5068 62720 23577 6 0.6491 5245 64910 27639 50.7380 5963 73800 37022

It is noted that all values in the above table are approximate andprovided for exemplary purposes only. As can be seen from the abovetable, the discontinuous operation (e.g. cycling between on and offstates) of the furnace during a heat call decreases an amount of fuelused during the heat call while the heat recovered during the latent,source and residual heating periods by the heat recovery assembly/system100 increases the fuel conversion efficiency of the furnace 2000.

During the latent, source and residual heating periods (e.g.respectively the period where the furnace 2000 is warming the furnaceheat exchanger FHX, the periods the furnace is on and the periods wherethe furnace 2000 is turned off during the heat call) one or more stagesof the multiple stage heat exchanger 120EX operate as described hereinto increase, balance or otherwise continue heat transfer to the returnair travelling through the return plenum 1300 for heating the supply airdelivered to the habitat through the supply plenum 1301. For example, inaccordance with aspects of the disclosed embodiment, the stage onecompressor 150 runs substantially 100% of the time (e.g. when thefurnace is on and when the furnace is off) the during a full thermostatheat call cycle (e.g. a duration of the heat call) so as to extract heat(e.g. residual furnace heat) from the chamber 110 and transfer heat tothe supply air. In one aspect the secondary compressor 150A only runswhile the furnace is turned on (e.g. the furnace burners FBRN are lit)while in other aspects the secondary compressor 150A also runs when thefurnace burners FBRN are not lit (e.g. the furnace is turned off). Inother aspects, the first and second stages of the heat exchange systemare operated at any suitable times, either together or individually,during the heat call. For example, in one aspect, only stage oneoperates during furnace off times and only stage two operates duringfurnace on times or vice versa. In another aspect, stage one operates toa point where a temperature of the supply air reaches a predeterminedtemperature at which time stage one is turned off and stage two isturned on, or vice versa. In one aspect, the controller 1311 isconfigured to stagger a starting of the stage one compressor 150 and thestage one compressor 150A to, for example, avoid a combined electricalsurge of the compressors 150, 150A.

As may be realized, the heat recovery assembly/system 100 describedherein is adapted to attach to or otherwise interface with any suitablefurnace having any age or configuration. In one aspect the assembly 100may be attached to a furnace with about 78% AFUE or higher efficiency,resulting in an increased efficiency of the system. Carbon discharge,exhaust gas temperature, and humidity may also be reduced if theassembly 100 is employed with a furnace.

Still referring to FIGS. 1 and 3, in one aspect a pressure sensors S5placed the heat recovery chamber exhaust 118 and is connected to thecontroller 1311 in any suitable manner (such as through a wired orwireless connection). The pressure sensors S2 is configured to monitoran exhaust vent pressure of the furnace 2000 and/or heat recoveryassembly 100 and send any suitable signal to the controller to turn thefurnace off if the exhaust vent pressure exceeds a predeterminedpressure and to turn the furnace back on if be exhaust, vent pressurefalls below the predetermined pressure. The controller 1311 isconfigured to, based on the signals from the sensor S2, to turn off thefurnace 2000 by interrupting the heat call from the thermostat TSH. Inone aspect, a temperature sensor S3 is disposed in the heat recoverychamber exhaust 118 and is connected to the controller 1311 formonitoring the exhaust gas exiting the heat recovery chamber. Where thesensor S3 detects the exhaust gas has a temperature above any suitablepredetermined threshold temperature the controller 1311 is configuredto, based on the sensor S3 signals, turn off the furnace 2000 byinterrupting the heat call from the the at TSH. In one aspect, atemperature sensor S1 is disposed in the furnace exhaust 2100/intake 114and is connected to the controller 1311 for monitoring a temperature ofthe exhaust gas entering the heat recovery chamber from the furnace 2000(or in other words monitoring of the exhaust gas exiting the furnace2000). Where the sensor S1 detects the exhaust gas from the furnace 2000passing through the intake 114 is below a predetermined temperaturethreshold the controller 1311 is configured to, based on the sensor S1signals, turn off the compressor(s) 150, 150A to protect thecompressor(s) 150, 150A and substantially prevent freezing of the heatexchange elements 116A, 116B. In one aspect each fluid circuit 120, 120Aincludes a temperature sensor S5, S6 for monitoring a temperature of thecooling fluid within the respective fluid circuit 120, 120A. Thetemperature sensors S5, S6 are connected to the controller 1311 andsuitable signals to the controller when, for example, a low temperaturethreshold is met so that the controller 1311 effects a defrosting of theheat exchange elements 116A, 116B in any suitable manner.

Referring next to FIG. 5 and FIG. 10, a heat recovery system 200 isillustrated in accordance with aspects of the disclosed embodiment. Thesystem 200 may include a furnace 2000 comprising an exhaust 2100 and afurnace intake 2300. The system 200 further includes heat recoverychamber 110 having a cooling intake 112 and an exhaust gas intake 114.In other aspects the system 200 may include a premix chamber 110A, 110Cand a heat exchange chamber 110B as described above with respect toFIGS. 11 and 12. The exhaust gas intake 114 may be configured to becommunicably coupled to (e.g. in communication with) the exhaust 2100 ofthe furnace to receive exhaust gas resulting from fuel combustion in thefurnace 2000. A first heat exchanger 116A may be disposed within theheat recovery chamber 110 and is in fluid communication with a fluidcircuit 120 that includes a conduit 122 configured to convey a fluidtherein, such as a refrigerant. In other aspects the first heatexchanger 116, which includes heat exchange element 116A, may becommunicably disposed outside the heat recovery chamber. The first heatexchanger 116 may be configured such that during operation of thefurnace 2000 it is in thermal communication with a mixture comprisingcooling gas introduced via the cooling intake 112 and exhaust gasintroduced via the exhaust gas intake 114 that is connected to thefurnace exhaust 2100.

The system 200 may include a second heat exchanger 130, which includesheat exchange element 130A, in fluid communication with the fluidcircuit 120 and disposed in thermal communication with an airstreambeing drawn into the furnace for heating (see INDOOR AIR passing throughthe second heat exchanger 130 in FIG. 5). Refrigerant is heated in thefirst heat exchanger 116 and moved to the second heat exchanger 130 viathe pressure gradient created by the heat exchange and, optionally, withassistance from any suitable compressor such as the micro-compressor orthe like (as described above), where heat exchange occurs between theairstream flowing from the indoor air source and the second heatexchanger 130. The preheated air from the second heat exchanger 130 isdirected into the heat exchanger 2200 of the furnace such that the airis further heated and then directed into the home or other habitablestructure for heating the home or other habitable structure.

The system 200 may include a drain 111 exiting the heat recovery chamber110. The drain 111 may be substantially similar to that described aboveand structured as, for example, in FIG. 1 or FIG. 2, depending on thetype of furnace being utilized in the system 200 (as explainedpreviously herein). As may be realized, a system 200 including the drain111 as illustrated in FIG. 2 would include a third heat exchanger 117 aspreviously described herein.

The system 200 may also include any suitable compressor 150 that may besubstantially similar to that previously described herein. In one aspectthe compressor may be a micro-compressor to aid in energy conservation.In another aspect a furnace inducer blower, IB, may be in connectionwith the furnace exhaust 2100 to actively draw exhaust from the furnace2000 into the exhaust gas intake 114 of the heat recovery chamber 110.

The assembly 100 and system 200 of the disclosed embodiment may furtherinclude a heat recovery ventilator. Heat recovery ventilators have beena known art in the HVAC industry for many years: however, the typicalventilator is much less efficient and structurally different than theaspects of the disclosed embodiment in combination with the assembly andsystem herein. A conventional Heat Recovery Ventilator (HRV) draws infresh outdoor air to replace exhausted indoor air. The HRV helps createair exchanges within home or building structures which in turn helps toreduce pollutants, smoke, contaminants, airborne allergies, viruses,etc. from collecting within the home or building ventilation systems.During the air exchange process of a ventilator, fans and heatexchangers will pass heated or cooled indoor air over unconditionedoutdoor air. The two air masses never combine but are separated by heatexchangers. This process can transfer as much as 85% of the heat energyfrom the conditioned air mass to the unconditioned air mass. About 15%of the energy is lost in this process, causing the home or buildingowner the expense of heating or air conditioning that loss to the newlyintroduced unconditioned air in order to maintain the same comfort levelwithin the structure.

Referring to FIGS. 5A and 10A a heat recovery system 200′ is illustratedin accordance with aspects of the disclosed embodiment. The heatrecovery system 200′ is substantially similar to heat recovery system200 described above with respect to FIGS. 5 and 10 however, in thisaspect the heat recovery system also includes the stage two coolingcircuit 120A as described above. As such, the first heat exchanger 116of the heat recovery system 200′ includes heat exchange elements 116Aand 116B disposed in the heat recovery chamber 110 and the second heatexchanger 130 includes heat exchange elements 130A and 130B throughwhich the indoor air passes for pre-heating the indoor air. As can beseen in FIG. 5A the cool, dry exhaust gas (e.g. cooling gas) introducedin the heat recovery chamber through cooling intake 112 is, in oneaspect mixed with recovery indoor air introduced into the cooling intake112 in any suitable manner such as by any suitable fan while in otheraspects, the recovery air is omitted. It is also noted that the fan orblower 140 is positioned to suck or draw the gases through the heatrecovery chamber 110 while in other aspects, the fan is located in anysuitable location for moving the gases through the heat recovery chamber110.

FIG. 6 illustrates a heat recovery ventilator (HRV) assembly 160configured in relation to a heat recovery assembly 100 for providingfresh outdoor air to the interior environment in accordance with aspectsof the disclosed embodiment. The HRV contains a ventilator outdoor airintake 162 that is structured to be in communication with the secondheat exchanger 130 for heating outdoor air as it is drawn into the airintake of a heating apparatus or furnace. The HRV provides clean,outdoor air for circulation within the home or building. It directs theair into the airstream being drawn across the second heat exchanger 130such that it can be heated by the energy efficient process of the heatrecovery assembly 100 or system 200, as previously described herein. Inone aspect the HRV assembly 160 may include a motorized damper 164 incommunication with the outdoor air intake 162 such that the flow ofoutdoor air is regulated. A thermostat 166 may be in communication withthe motorized damper 164 for controlling the opening and closing of thedamper 164 based on the outdoor air temperature. In one aspect thedamper 164 may allow air temperatures ranging from about 10° F. to about70° F. to pass therethrough. In other aspects the damper 164 may allowair having any suitable temperature to pass therethrough. The thermostat166 may include a temperature sensor 168 to communicate the outside airtemperature. In one aspect the inducer blower, such as fan or blower140B is located on an outlet side (e.g. on a side of the heat exchangerwhere the combined cooling gas and exhaust gas exit from the heatexchanger) of the heat recovery chamber 110 so that gas is “pulled”through the first heat exchanger 116 while in other aspects the fan islocated at any suitable location for moving gas through the heatrecovery chamber.

FIG. 7 illustrates an electrical wiring diagram of a heat and energyrecovery system in accordance with aspects of the disclosed embodiment.The diagram illustrates the connections between a logic board or othersuitable controller 1311 of the system and the furnace control board andthermostat of an HVAC system. In one aspect, the logic board orcontroller 1311 may include a LCD scroll display 171 for a visualdepiction of the operational parameters of the system. Heat recovery,troubleshooting, and normal operating conditions may be indicated by LEDlights (see “POWER”, “TROUBLE”, “COMP1” and “COMP2”) or in any othersuitable visual and/or aural manner. Various connections between sensorsand switches (e.g., low and high pressure switches) are also depicted.The inducer blower or fan and micro-compressor connections and requisiterelays are also depicted but may not be provided such as when the systemdoes not include an inducer blower or compressor. Connections betweenone or more components of the system may be wired with the controller1311 to provide centralized control and functionality of the system.

FIGS. 8A, 8B and 9 illustrate operational aspects of the heat and energyrecovery system 200 with a furnace 2000 in accordance with the disclosedembodiment. As shown, the system 200 may be adapted to fit on thefurnace unit either on a wall of the (FIG. 8A) or in line with the airintake (e.g. return plenum) of the furnace (FIG. 9). In other aspectsthe system 200 may have any suitable positional relationship relative tothe furnace 2000. A cut-away illustration is shown in FIG. 10 where, inone aspect of the disclosed embodiment, the system 200 is structured tobe in line with the furnace intake 2300 (which is substantially similarto return plenum 1300) for receiving air as it is drawn into the furnace2000. As can be seen in FIG. 8A, different configurations with respectto the placement of the return plenum 1300, the recovery chamber 110 andthe first and second heat exchangers 116, 130 relative to the furnace2000.

In one aspect the heat recovery system 100, 200, 200′ may substantiallybe a modular unit that can be connected to, for example, furnace 2000having a common housing 200HA (such as that shown in FIG. 9) in which atleast the first and second heat exchangers 116, 130 are located. In one,aspect the heat recovery system 100, 200, 200′ has a two part modularconfiguration such that the first heat exchanger 116 is included in onemodular 200A unit having a first housing 200HB and the second heatexchanger is included in another modular unit 200B having a secondhousing 200HC that can be placed at different locations relative to eachother and/or the furnace 2000 or boiler such as illustrated in FIG. 8A.In other aspects the heat recovery system 100, 200, 200′ includes morethan two modules where each module includes one or more of the heatexchange elements of the first and second heat exchangers 116, 130, forexample, additional heat exchangers and/or other components of the heatrecovery system 100, 200 may be disposed in respective modular unitseach having a respective housing for placement at any suitable locationrelative to other modular units. Also referring to FIG. 8B the modularunit 200A may include the first heat exchanger 116, the recovery chamber110 and any other suitable components of the heat recovery system 100,200, 200′ such as one or more of the features illustrated in FIGS. 7, 7Aand 7B. The modular unit 200B may include the second heat exchanger 130disposed within housing 200HC. As can be seen in FIG. 8B the modularunits 200A, 200B may be placed at any suitable locations relative toeach other and/or the furnace 2000 (or boiler) which in one aspect maydepend on available space in the installation location of the heatrecovery system 100. 200.

Referring to FIG. 15, in one aspect of the disclosed embodiment, atleast a portion of the heat recovery system may be integrated within ahousing 2000H of the furnace 2000. For example, in one aspect thehousing 2000H may house combustion chamber 2000CH and at least the firstheat exchanger 116 so that the furnace 2000 has an integral refrigerantheat exchange. In one aspect the first heat exchanger may be disposedwithin a heat exchange chamber 110B (e.g. substantially similar to thatdescribed with respect to FIG. 12) where a gas inlet is provided atleast partly in the housing 2000H for transferring combined exhaust gasand cooling gas to the first heat exchanger from the exhaust gas inlet114 and cooling intake 112. In other aspects the first heat exchanger116 may be disposed within the heat recovery chamber 110 (which isdisposed within the housing 2000CH) while in other aspects the heatrecovery chamber 110, 110B may be separate from a heat exchange chamber110B (where the first heat exchanger is located within the heat exchangechamber 110B) as described above with respect to FIGS. 11 and 12. As maybe realized, the heat recovery chamber 110, 110B and the heat exchangechamber 110B may be disposed within the housing 1200CH such that theexhaust inlet 114 and cooling intake 112 (located at least partly withinthe housing) provide exhaust gas and cooling gas to the combiningchamber. In one aspect, the housing may also house the second heatexchanger 130 that is communicably connected to the first heat exchangerthrough one or more of conduits 120, 120A.

Referring to FIG. 13 a modular heat recovery system shown in accordancewith the aspects of the disclosed embodiment. In this aspect the returnplenum 1300 returns air from the heating space to the furnace to beheated. In one aspect outdoor or ventilation air may be introduced tothe return air through duct 1303 which may include a blower or fan (inother aspects a fan may not be provided) for moving the outdoor air intothe return plenum 1300. The modular unit 200B may be located, forexample, between the furnace 2000 and the return plenum 1300, within aninternal passage of the return plenum 1300 and/or in-line with thereturn plenum 1300. As described above, heat from the second heatexchanger 130 may be transferred to the return air for heating orotherwise pre-heating the return air prior to heating the air with thefurnace 2000. As may be realized, the heated air may be transferredthrough the supply plenum 1301 back to the heating space. In one aspect,any suitable filter 1302 may be disposed in or in-line with the returnplenum 1300 so that filtered air is provided for contacting the secondheat exchanger 130. The modular unit 200A may be located at any suitablelocation relative to one or more of the modular unit 200B and thefurnace 2000. The modular unit 200A, in this aspect, includes the heatrecovery chamber 110 and first heat exchanger 116 (which may be incommunication with the second heat exchanger through conduit circuit120) and blower 140. In other aspects the modular unit 200A may includeany suitable components of the heat recovery system as described herein.Exhaust gas from the furnace and cooling gas may be provided to the heatrecovery chamber 110 through cooling intake 112 and exhaust intake 114in a manner substantially similar to that described above. In thisaspect the blower 140 is provided to pull or draw gas through the heatrecovery chamber 110.

Any suitable sensor(s) 1310 may be may be provided for sensing apressure (or other suitable physical characteristic of the gas withinthe heat recovery chamber) for determining a pressure within the heatrecovery chamber 110. The sensor(s) 1310 may be connected to anysuitable controller 1311 (which may include one or more featuresdescribed above with respect to FIG. 7). In one aspect the controllermay be integral to the modular unit 200A while in other aspect thecontroller may be provided at any suitable location. The sensor(s) 1310may include a pressure sensor connected to the controller 1311 to form apressure switch for controlling a pressure within the heat recoverychamber 110. The cooling intake 112 may include any suitable bypassvalve 112V for redirecting, limiting or substantially preventingdischarge gas from entering the cooling intake 112 for maintaining apredetermined pressure within the heat recovery chamber 110. In oneaspect the valve 112V may be connected to the controller 1311 such thatwhen a predetermined pressure within the heat recovery chamber isdetected by the sensor(s) 1310 the controller operates the valve 112V todirect at least some of the discharge gas past the cooling intake 112for maintaining the predetermined pressure or any other suitablepressure. In other aspect the speed of the blower 140 may be adjusted bythe controller 1311 for maintaining the predetermined pressure. In otheraspects the controller may turn off the blower 140 to maintain thepredetermined pressure within the heat recovery chamber. As may berealized a check valve 1410V may be provided in one or more of the heatrecovery chamber exhaust 1410, exhaust inlet 114 and cooling intake 112to substantially prevent a back flow of gas into the heat recoverychamber where a pressure within the heat recovery chamber is lower thanatmospheric pressure outside the heat recovery chamber.

In another aspect, still referring to FIG. 13, the sensor(s) 1310 mayinclude a temperature sensor (similar to sensors CS1 CS2 describedabove) for sensing a temperature of the refrigerant within the firstheat exchanger 116. In this aspect any suitable blower or fan 1320 maybe provided for circulating air through the return plenum 1300 and thesupply plenum 1301. The blower 1320 may be connected to the controller1311 in any suitable manner. As may be realized, as the furnace 2000 isoperating the exhaust from the furnace heats the refrigerant within thefirst and second heat exchangers 116, 130 and the conduit circuit 120.When the furnace 2000 turns off there may be residual heat stored in thecombustion chamber 2000CH of the furnace as well as in the refrigerant.The residual heat from the combustion chamber 2000CH may be drawn fromthe combustion chamber in any suitable manner, such as by gas flowingthrough the combustion chamber and into the heat recovery chamber 110through the exhaust intake. Any suitable blower or fan may be providedfor drawing gas from the combustion chamber into the heat recoverychamber when the furnace 2000 is not operating (e.g. turned off). Inother aspect the air flow may be provided through convection. In thisaspect heated gas from the combustion chamber 2000CH alone or incombination with cooling gas from the cooling intake 112 may continue tobe provided to the heat recovery chamber after the furnace 2000 isturned off. This heated gas may continue to heat the refrigerant withinthe first heat exchanger 116 for transfer to the second heat exchangerwhere that heat is extracted from the second heat exchanger by the airflowing in the return and supply plenums 1300, 1301 so that heated airis provided to the heating space after the furnace is turned off. Thesensor(s) 1310 may send a signal to the controller 1311 when thetemperature of, for example, the refrigerant reaches a predeterminedtemperature. When the predetermined temperature is reached thecontroller 1311 may turn off the one or more of the blowers 1320, 140 tostop the flow of air into the heating space or adjust a speed of theblowers to decrease the flow of air. In this aspect, any residual heatfrom the furnace may be extracted which may increase the energyrecovered by the system 100, 200. In other aspects, the extraction ofresidual heat from the furnace may be performed in the manner describedabove using pressure readings from within the heat recovery chamber. Forexample, the blowers may be turned off or the speed of the blower may bevaried (e.g. decreased) when the pressure within the heat recoverychamber reaches any suitable predetermined pressure. In, still otheraspects pressure and temperature readings may be used to control theblowers for the recovery of residual heat from tile furnace.

In other aspects the sensor(s) 1310 may be configured to detect apressure of the refrigerant within the first heat exchanger 116 and/or atemperature of the first heat exchanger 116 for determining the presenceof frost on the first heat exchanger. For example, a compressor 150 maybe provided to at least partly effect the flow of refrigerant throughthe conduit circuit 120 as described above. The sensor(s) 1310 may beconfigured to send signals to, for example, controller 1311 indicating adecrease in pressure and/or temperature within the first heat exchangerat which frost may form. The controller may be configured to, based onthe sensor signals, turn off the compressor 150 so that the temperatureand pressure of the first heat exchanger 116 rise to allow dissipationof the frost. The controller 1311 may be configured to use the sensordata (in e.g. in a closed loop feedback system) for setting, compressor150 on/off times where the compressor on/off times may be adjusted bythe controller in predetermined time increments.

Referring now to FIG. 14A, in the aspects of the disclosed embodimentdescribed herein the heat recovery chamber 110, 110A, 110C may have anysuitable configuration for mixing the exhaust gas from exhaust intake114 and the cooling gas from cooling intake 112. In one aspect the heatrecovery chamber may have one or more features for mixing the exhaustgas and cooling gas. For example, ends of the cooling intake 112 andexhaust intake 114 within the heat recovery chamber may be angledtowards a wall or mixing surface 110S (e.g. the walls may be contouredor textured) of the heat recovery chamber 110 so that the exhaust gasand cooling gas are reflected by the wall or mixing surface it anysuitable manner for mixing or otherwise combining the exhaust gas withthe cooling gas. In another aspect the heat recovery chamber 110, 11Bmay include one or more vanes 1400 configured to direct the exhaust gasand cooling gas in any suitable direction(s) for mixing or otherwisecombining the exhaust gas and cooling gas. In yet another aspect theheat recovery chamber 110, 110B may include any suitable diffuser 1402or other suitable mixing element for mixing or otherwise combining theexhaust gas and cooling gas. In still other aspects, the heat recoverychamber 110, 110B may include one or more of the mixing surface 110S,vanes 1400, diffuser(s) 1402 and/or any other suitable mixing structurefor mixing or otherwise combining the exhaust gas and cooling gasprovided by the exhaust gas intake 114 and the cooling intake 112.

Referring to FIG. 14B and FIG. 14C the heat recovery chamber 110, 110Bmay be configured so that the exhaust inlet 114 and cooling intake 112are disposed on opposing sides or sides of the heat recovery chamber110, 110B that are angled relative to one another. For example, as canbe seen in FIG. 14B the exhaust gas intake 114 and the cooling intake112 are disposed on opposing sides of the heat recovery chamber 110,110B so that the intakes substantially face one another. In this aspectthe exhaust gas and cooling gas may be opposingly directed towards oneanother for mixing. As may be realized, the exhaust intake 114 andcooling intake 112 may be vertically or horizontally offset with oneanother or in-line with one another so that the exhaust gas and coolinggas provided to the heat recovery chamber impinge each other at anypredetermined angle. As may also be realized, in one aspect, where thefirst heat exchanger 116 is located within the heat recovery chamber110, the first heat exchanger may be disposed between an outlet orexhaust 1410 of the heat recovery chamber and the inlets 114, 112 sothat the mixture of exhaust gas and cooling gas passes through the firstheat exchanger 116 before entering the outlet or exhaust 1410. Inanother aspect, where the first heat exchanger 116 is located in aseparate heat exchange chamber 110B (e.g. such as described above withrespect to FIGS. 11 and 12) the mixture of exhaust gas and cooling gasmay exit the heat recovery chamber through outlet or exhaust 1410 fortransfer to the heat exchange chamber 110B.

As can be seen in FIG. 14C and 14D, the exhaust gas intake 114 andcooling intake 112 may be disposed on angled sides of the heat recoverychamber in any suitable manner such as in a manner described withrespect to FIG. 14. As may be realized, where the first heat exchanger116 is located within the heat recovery chamber 110, the first heatexchanger may be disposed between the outlet or exhaust 1410 of the heatrecovery chamber and the inlets 114, 112 so that the mixture of exhaustgas and cooling gas passes through the first heat exchanger 116 beforeentering the outlet or exhaust 1410. In another aspect, where the firstheat exchanger 116 is located in a separate heat exchange chamber 110B(e.g. such as described above with respect to FIGS. 11 and 12) themixture of exhaust gas and cooling gas may exit the heat recoverychamber through outlet or exhaust 1410 for transfer to the heat exchangechamber 110B.

Referring to FIG. 14E, in accordance with an aspect of the disclosedembodiment the first heat exchanger may have any suitable configuration.In one aspect the first heat exchanger 116 may have a planarconfiguration while in other aspects the first heat exchanger 116′(which includes one or more of heat exchange elements 116A′, 116B′ whichare substantially similar to heat exchange elements 116A, 116B describedabove) may have cylindrical configuration. For example, first the heatexchange element 116A′ may substantially divide the heat recoverychamber into a first portion 110P1 and second portion 110P2 and whereprovided the heat exchanger 116B further divides the heat recoverychamber into at least a third portion disposed between the secondportion and the exhaust 1410). The exhaust gas and cooling gas isintroduced into the first portion 110P1 and the mixture of the exhaustgas and cooling gas exits through the second portion 110P2 where themixed gas passes from the first portion 110P1 through the first heatexchanger 116A to the second portion 110P2, and in one aspect, throughthe heat exchanger 116B. In this example the first heat exchanger 116Amay include coils arranged in a cylindrical arrangement so as to have aninterior that forms the second portion 110P2 (and/or the heat exchanger116B has coils arranged in a cylindrical arrangement to form at leastthe third portion). The exhaust gas and cooling gas is introduced intothe first portion, passes through the coils of the first heat exchanger116A to the interior and then, in one aspect, through the coils of theheat exchanger 116B and exits the outlet or exhaust 1410. In anotheraspect, as shown in FIG. 14F, the exhaust gas and cooling gas enters theinterior of the first heat exchanger (e.g. into portion 110P2) passesthrough the coils of the first heat exchanger 116A to the first portion110P1 where the gas, in one aspect passes through heat exchanger 116B,and exits through the outlet or exhaust 1410. In other aspects the heatexchanger 116B is is omitted.

Referring to FIG. 16 the heat recovery system described herein can beemployed with a boiler system 1600 to provide heated air to a heatingspace 1650 within a habitable structure. For example, exhaust gas fromboiler 1600 may be provided to heat recovery chamber 110 through exhaustgas inlet 114. Cool dry gas (such as for example, indoor air and/orcooling gas from the heat recovery chamber as described above) isprovided to the heat recovery chamber 110 through cooling intake 112.The combined exhaust gas and cooling gas contacts the first heatexchanger 116 (which includes one or more of heat exchange elements116A, 116B) and at least a portion of the exhaust gas exits outside thehabitable structure through exhaust 1410. Heat is transferred from thefirst heat exchanger 116 to the second heat exchanger 130 (whichincludes one or more of heat exchange elements 130A, 130B) throughconduit 120 (and/or conduit 120A) as described above. The second heatexchanger 130 is disposed within or in line with an air delivery systemhaving a fan or blower 1621, a supply duct 1620 and one or more airregisters 1610, 1611 through which heated supply air is introduced tothe heating space 1650. In this aspect the second heat exchanger 130 isdisposed between the supply duct 1620 and the air registers 1610, 1611so that air forced through the supply duct by blower 1621 passes throughthe second heat exchanger 130 so that heat extracted from the secondheat exchanger heats the air for delivery into the heating space throughthe air registers 1610, 1611.

As may be realized, in one aspect, the heat transferred to the secondheat exchanger 130 from the first heat exchanger 116 (whether the systemis employed with a furnace or boiler) is used to heat any suitable heatsink or heat transfer medium. Referring to FIG. 17 in one aspect waterwithin a hot water tank 1700 is heated with the heat recovery systemdescribed herein. For example, an air duct 1710 may be disposed adjacenta water chamber 1700C of the hot water tank 1700. In this aspect the airduct 1710 is coiled around the water chamber 1700C while in otheraspects air duct(s) 1710 may be disposed within the water chamber 1700Cor have any other suitable spatial arrangement/configuration relative tothe water chamber 1700C for heating water within the water chamber 1700in the manner described herein. In one aspect the second heat exchanger130 may be disposed so air passing through the air duct 1710 is forcedor pulled through the second heat exchanger 130, in any suitable manner(such as by blower 140) before entering the air duct 1710. The secondheat exchanger 130 may heat the air so that as the heated air passesthrough the air duct 1710 heat is transferred from the air to the waterwithin the water chamber 1700C in any suitable manner. The air may bedrawn from the space in which the hot water tank 1700 is located or fromany other suitable source and exhausted back into the space in which thehot water tank is located or to any other suitable location (such asoutside the habitable space). As may be realized the flow rate of theair and/or the length of the air duct 1710 may be such thatsubstantially all of the heat stored in the air is transferred to thewater within the water chamber 1700C.

In one aspect the disclosed embodiment is directed to a method ofrecovering heat and energy from fuel combustion. The method includesfeeding excess heat and exhaust gas emitted as a result of fuelcombustion into a heat recovery chamber 110 which contains a first heatexchanger 116 (fluid filled) coupled with a fluid containing conduitcircuit(s) 120, 120A. Typically, the fluid comprises a refrigerant. Themethod further includes feeding cooling gas into the heat recoverychamber so that the cooling gas is mixed with the exhaust gas to producea mixed gas with potential energy. The method may also includeeffectuating heat energy exchange through the mixed gas and excess heatinteracting with the first heat exchanger 116. As a result, thetemperature and pressure within the first heat exchanger 116 and fluidcontaining conduit circuit(s) 120, 120A rises. The method may alsoinclude releasing the heat energy by, for example, forced (or any otherflow of) air blowing over a second heat exchanger 117 that is in fluidcommunication with one fluid containing conduit circuit(s) 120, 120Aexterior to the heat recovery chamber.

In accordance with one or more aspects of the disclosed embodiment aheat recovery system in a habitat to be heated by a furnace having acontroller coupled to a thermostat, the heat recovery system includes achamber including a cooling intake, an emissions intake and a chamberexhaust, the emissions intake is configured for receiving exhaust gasemitted as a result of fuel combustion in the furnace and the chamberexhaust is configured to discharge emissions from the chamber; a heatrecovery exchanger disposed within the chamber for contacting a mixtureof cooling gas introduced through the cooling intake and the exhaust gasintroduced through the emissions intake such that heat exchange iseffected; at least one fluid circuit in communication with the heatrecovery exchanger; a heat extraction exchanger in fluid communicationwith the heat recovery exchanger through the at least one fluid circuitto effect heat exchange between the heat extraction exchanger and anairstream running therethrough; and a temperature sensor located in asupply plenum of the furnace and having a predetermined hi temperatureset point and a predetermined low temperature set point; where thecontroller is configured so that in response to a heat call from thethermostat, the furnace is repeatedly cycled between on and off stateswhen the controller registers temperature sensor signals correspondingto the predetermined hi temperature set point and the predetermined lowtemperature set point.

It accordance with one or more aspects of the disclosed embodiment theheat recovery system further includes a pressure regulating assembly incommunication with the chamber and the chamber exhaust for regulating apressure in the heat recovery system.

In accordance with one or more aspects of the disclosed embodiment thepressure regulating assembly includes a fan communicably coupled to thechamber exhaust and configured to draw the emissions from the chamber.

In accordance with one or more aspects of the disclosed embodiment thecooling intake is communicably coupled to the chamber exhaust and isconfigured to extract at least a portion of the emissions forrecirculation as the cooling gas.

In accordance with one or more aspects of the disclosed embodiment theheat recovery exchanger and the heat extraction exchanger comprise amulti-stage heat exchange system including at least: a first stagehaving a primary heat recovery exchanger element and a primary heatextraction exchanger element communicably coupled to each other througha primary fluid circuit of the at least one fluid circuit; and a secondstage having a secondary heat recovery exchanger element and a secondaryheat extraction exchanger element communicably coupled to each otherthrough a secondary fluid circuit of the at least one fluid circuit.

In accordance with one or more aspects of the disclosed embodiment eachstage of the multi-stage heat exchange system is independently operablefrom another stage of the multi-stage heat exchange system.

In accordance with one or more aspects of the disclosed embodiment thefirst stage of the multi-stage heat exchange system effects heatexchange during both furnace on and off states.

In accordance with one or more aspects of the disclosed embodiment thesecond stage of the multi-stage heat exchange system is operative andeffects heat exchange during furnace on states and inoperative duringfurnace off states.

In accordance with one or more aspects of the disclosed embodiment aburner of the furnace is switched on and off corresponding to a furnaceon and off cycle and a return air blower of the furnace continues to runduring the heat call.

In accordance with one or more aspects of the disclosed embodiment, theheat recovery system is configured to be combined with a heating furnaceto effects the coupling of a PVC exhaust duct to the combination of theheat recovery assembly/system 100 and the furnace 2000.

In accordance with one or more aspects of the disclosed embodiment aheat recovery system includes a furnace having a furnace exhaust, areturn plenum and a controller coupled to a thermostat; a chamberincluding a cooling intake, an emissions intake and a chamber exhaust,the emissions intake being communicably coupled to the furnace exhaustso that exhaust gas emitted as a result of fuel combustion in thefurnace is transferred to the chamber, the chamber exhaust is configuredto discharge emissions from the chamber, and the cooling intake isconfigured to effect transfer of at least a portion of the emissionsfrom the chamber exhaust to the chamber as cooling gas; a heat recoveryexchanger disposed within the chamber for contacting a mixture of thecooling gas and the exhaust gas such that heat exchange is effected; atleast one fluid circuit in communication with the heat recoveryexchanger; a heat extraction exchanger in fluid communication with theheat recovery exchanger through the at least one fluid circuit and inthermal communication with an airstream running through the returnplenum for transferring heat from the heat extraction exchanger to theairstream; and a temperature sensor located in a supply plenum of thefurnace and having a predetermined hi temperature set point and apredetermined low temperature set point; where the controller isconfigured so that in response to a heat call from the thermostat, thefurnace is repeatedly cycled between on and off states throughout theheat call when the controller registers temperature sensor signalscorresponding to the predetermined hi temperature set point and thepredetermined low temperature set point.

In accordance with one or more aspects of the disclosed embodiment theheat recovery system further includes a pressure regulating assembly incommunication with the chamber and the chamber exhaust for regulating apressure in the heat recovery system.

In accordance with one or more aspects of the disclosed embodiment thepressure regulating assembly includes a fan communicably coupled to thechamber exhaust and configured to draw the emissions from the chamber.

In accordance with one or more aspects, of the disclosed embedment theheat recovery exchanger and the heat extraction exchanger comprise amulti-stage heat exchange system including at least: a first stagehaving a primary heat recovery exchanger element and a primary heatextraction exchanger element communicably coupled to each other througha primary fluid circuit of the at least one fluid circuit; and a secondstage having a secondary heat recovery exchanger element and a secondaryheat extraction exchanger element communicably coucoupled to each otherthrough a secondary fluid circuit of the at least one fluid circuit.

In accordance with one or more aspects of the disclosed embodiment eachstage of the multi-stage heat exchange system is independently operablefrom another stage of the multi-stage heat exchange system.

In accordance with one or more aspects of the disclosed embodiment thefirst stage of the multi-stage heat exchange system effects heatexchange during both furnace on and off states.

In accordance with one or more aspects of the disclosed embodiment thesecond stage of the multi-stage heat exchange system is operative andeffects heat exchange during furnace on states and inoperative duringfurnace off states.

In accordance with one or more aspects of the disclosed embodiment aburner of the furnace is switched on and off corresponding to a furnaceon and off cycle and a return air blower of the furnace continues to runduring the heat call.

In accordance with one or more aspects of the disclosed embodiment thechamber exhaust comprises a PVC duct.

In accordance with one or more aspects of the disclosed embodiment aheating furnace includes a furnace exhaust; a return plenum; acontroller coupled to a thermostat; and a heat recovery system includinga chamber including a cooling intake, an emissions intake and a chamberexhaust, the emissions intake being communicably coupled to the furnaceexhaust so that exhaust gas emitted as a result of fuel combustion inthe furnace is transferred to the chamber, the chamber exhaust isconfigured to discharge emissions from the chamber, and the coolingintake is configured to effect transfer of at least a portion of theemissions from the chamber exhaust to the chamber as cooling gas; a heatrecovery exchanger disposed within the chamber for contacting a mixtureof the cooling gas and the exhaust gas such that heat exchange iseffected; at least one fluid circuit in communication with the heatrecovery exchanger; a heat extraction exchanger in fluid communicationwith the heat recovery exchanger through the at least one fluid circuitand in thermal communication with an airstream running through thereturn plenum for transferring heat from the heat extraction exchangerto the airstream; and a temperature sensor located in a supply plenum ofthe furnace and having a predetermined hi temperature set point and apredetermined low temperature set point; where the controller isconfigured so that in response to a heat call from the thermostat, thefurnace is repeatedly cycled, for a duration of the heat call, betweenon and off states when the controller registers temperature sensorsignals corresponding to the predetermined hi temperature set point andthe predetermined low temperature set point.

In accordance with one or more aspects of the disclosed embodiment theheating furnace further includes a pressure regulating assembly incommunication with the chamber and the chamber exhaust for regulating apressure in the heat recovery system.

In accordance with one or more aspects of the disclosed embodiment thepressure regulating assembly includes a fan communicably coupled to thechamber exhaust and configured to draw the emissions from the chamber.

In accordance with one or more aspects of the disclosed embodiment theheat recovery exchanger and the heat extraction exchanger comprise amulti-stage heat exchange system including at least a first stage havinga primary heat recovery exchanger element and a primary heat extractionexchanger element communicably coupled to each other through a primaryfluid circuit of the at least one fluid circuit; and a second stagehaving a secondary heat recovery exchanger element and a secondary heatextraction exchanger element communicably coupled to each other througha secondary fluid circuit of the at least one fluid circuit.

In accordance with one or more aspects of the disclosed embodiment eachstage of the multi-stage heat exchange system is independently operablefrom another stage of the multi-stage heat exchange system.

In accordance with one or more aspects of the disclosed embodiment thefirst stage of the multi-stage heat exchange system effects heatexchange during both furnace on and off states.

In accordance with one or more aspects of the disclosed embodiment thesecond stage of the multi-stage heat exchange system is operative andeffects heat exchange during furnace on states and inoperative duringfurnace off states.

In accordance with one or more aspects of the disclosed embodiment aburner of the furnace is switched on and off corresponding to a furnaceon and off cycle and a return air blower of the furnace continues to runduring the heat call.

In accordance with one or more aspects of the disclosed embodiment aheat recovery system, in a habitat to be heated by a furnace having acontroller coupled to a thermostat, includes a chamber including acooling intake, an emissions intake and a chamber exhaust, the emissionsintake is configured for receiving exhaust gas emitted as a result offuel combustion in the furnace and the chamber exhaust is configured todischarge emissions from the chamber; a multiple stage heat recoveryexchanger disposed within the chamber for contacting a mixture ofcooling gas introduced through the cooling intake and the exhaust gasintroduced through the emissions intake such that heat exchange iseffected, the multiple stage heat recovery exchanger including at leasta first stage and a second stage; at least one fluid circuit incommunication with the heat recovery exchanger; a multiple stage heatextraction exchanger in fluid communication with the heat recoveryexchanger through the at least one fluid circuit to effect heat exchangebetween the heat extraction exchanger and an airstream runningtherethrough, the multiple stage heat extraction exchanger having atleast a first stage and a second stage; and a temperature sensor locatedin a supply plenum of the furnace and having a predetermined hitemperature set point and a predetermined low temperature set point;where the controller is configured so that in response to a heat callfrom the thermostat, one or more of the first and second stages of themultiple stage heat recovery exchanger and the multiple stage heatextraction exchanger are operative during the furnace on state, thefirst stages of the multiple stage heat recovery exchanger and themultiple stage heat extraction exchanger are operative during thefurnace on state, and the second stages of the multiple stage heatrecovery exchanger and the multiple stage heat extraction exchanger areinoperative during the furnace off state.

In accordance with one or more aspects of the disclosed embodiment theheat recovery system further includes a pressure regulating assembly incommunication with the chamber and the chamber exhaust for regulating apressure in the heat recovery system.

In accordance with one or more aspects of the disclosed embodiment thepressure regulating assembly includes a fan communicably coupled to thechamber exhaust and configured to draw the emissions from the chamber.

In accordance with one or more aspects of the disclosed embodiment thecooling intake is communicably coupled to the chamber exhaust and isconfigured to extract at least a portion of the emissions forrecirculation as the cooling gas.

In accordance with one or more aspects of the disclosed embodiment thecontroller is configured so that in response to a heat call from thethermostat the furnace is repeatedly cycled between on and off stateswhen the controller registers temperature sensor signals correspondingto the predetermined hi temperature set point and the predetermined lowtemperature set point.

In accordance with one or more aspects of the disclosed embodiment thechamber exhaust comprises a PVC duct.

In accordance with one or more aspects of the disclosed embodiment aheat recovery system, in a habitat to be heated by a furnace having acontroller coupled to a thermostat, includes a chamber including anemissions intake, a chamber exhaust and a closed loop cooling intakecommunicably coupling the chamber exhaust and the chamber, the emissionsintake is configured for receiving exhaust gas emitted as a result offuel combustion in the furnace, the chamber exhaust is configured todischarge emissions from the chamber and the cooling intake isconfigured to recirculate at least a portion of the emissions from thechamber exhaust to the chamber; a heat recovery exchanger disposedwithin the chamber for contacting a mixture of cooling gas introducedthrough the cooling intake and the exhaust gas introduced through theemissions intake such that heat exchange is effected; at least one fluidcircuit in communication with the heat recovery exchanger; a heatextraction exchanger in fluid communication with the heat recoveryexchanger through the at least one fluid circuit to effect heat exchangebetween the heat extraction exchanger and an airstream runningtherethrough; and a temperature sensor located in a supply plenum of thefurnace and having a predetermined hi temperature set point and apredetermined low temperature set point; where the controller isconfigured so that in response to a heat call from the thermostat, thefurnace is repeatedly cycled between on and off states when thecontroller registers temperature sensor signals corresponding to thepredetermined hi temperature set point and the predetermined lowtemperature set point.

In accordance with one or more aspects of the disclosed embodiment theheat recovery system further includes a fan communicably coupled to thechamber exhaust and configured to draw the emissions from the chamber.

In accordance with one or more aspects of the disclosed embodiment theheat recovery exchanger and the heat extraction exchanger comprise amulti-stage heat exchange system including at least: a first stagehaving a primary heat recovery exchanger element and a primary heatextraction exchanger element communicably coupled to each other througha primary fluid circuit of the at least one fluid circuit; and a secondstage having a secondary heat recovery exchanger element and a secondaryheat extraction exchanger element communicably coupled to each otherthrough a secondary fluid circuit of the at least one fluid circuit.

In accordance with one or more aspects of the disclosed embodiment eachstage of the multi-stage heat exchange system is independently operablefrom another stage of the multi-stage heat exchange system.

In accordance with one or more aspects of the disclosed embodiment thefirst stage of the multi-stage heat exchange system effects heatexchange during both furnace on and off states.

In accordance with one or more aspects of the disclosed embodiment thesecond stage of the multi-stage heat exchange system is operative andeffects heat exchange during furnace on states and inoperative duringfurnace off states.

In accordance with one more aspects of the disclosed embodiment thechamber exhaust comprises a PVC duct.

In accordance with one or more aspects of the disclosed embodiment amethod for recovering heat in a habitat heated by a furnace includesproviding a chamber including a cooling intake, an emissions intake anda chamber exhaust, where the emissions intake receives exhaust gasemitted as a result of fuel combustion in the furnace and the chamberexhaust discharges emissions from the chamber; providing a heat recoveryexchanger disposed within the chamber for contacting a mixture ofcooling gas introduced through the cooling intake and the exhaust gasintroduced through the emissions intake such that heat exchange iseffected; providing a heat extraction exchanger in fluid communicationwith the heat recovery exchanger through at least one fluid circuit foreffecting heat exchange between the heat extraction exchanger and anairstream running therethrough; providing a temperature sensor in asupply plenum of the furnace and having a predetermined hi temperatureset point and a predetermined low temperature set point; and repeatedlycycling the furnace, with a controller that, in response to a heat callfrom a thermostat, repeatedly cycles the furnace between on and offstates for a duration of the heat call when the controller registerstemperature sensor signals corresponding to the predetermined hitemperature set point and the predetermined low temperature set point.

In accordance with one or more aspects of the disclosed embodiment themethod further includes regulating a pressure within the chamber withfan communicably coupled to the chamber exhaust where the emissions aredrawn from the chamber.

In accordance with one or more aspects the disclosed embodiment themethod further includes supplying cooling gas in a closed loop from thechamber exhaust to the cooling intake.

In accordance with one or more aspects of the disclosed embodiment theheat recovery exchanger and the heat extraction exchanger are providedas a multi-stage heat exchange system including at least; a first stagehaving a primary heat recovery exchanger element and a primary heatextraction exchanger element communicably coupled to each other througha primary fluid circuit of the at least one fluid circuit; and a secondstage having a secondary heat recovery exchanger element and a secondaryheat extraction exchanger element communicably coupled to each otherthrough a secondary fluid circuit of the at least one fluid circuit.

In accordance with one or more aspects off the disclosed embodiment themethod further includes effecting heat exchange during both furnace onand off states with the first stage of the multi-stage heat exchangesystem.

In accordance with one or more aspects of the disclosed embodimentmethod further includes effecting heat exchange during furnace on stateswith the second stage of the multi-stage heat exchange system.

In accordance with one or more aspects of the disclosed embodiment aburner of the furnace is switched on and off corresponding to a furnaceon and off cycle and a return air blower of the furnace continues to runduring the heat call.

Referring to FIG. 19, ire accordance with one or more aspects of thedisclosed embodiment, the system includes at least one controller 202operably linked to respective operating components (e.g., and/oroperating zones) of the heat recovery system. For example, the operatingcomponents coupled to the at least one controller includes a compressor,a condenser, a heat exchanger, a meter, a fan, a motor, a rotor, acircuit, a pump, a valve, a conductor, a capacitor, a switch and otherfunctional components.

The system also includes at least one sensor 204 configured to collectat least one environmental measurement and system-related data. Theenvironment measurement and the system related data includes internaland external temperature and pressure humidity, barometric pressures,dew points, wind direction, sun peak and angle, annual precipitation,geographical location and, elevation of the system, thermostatssettings, chemical analysis at specific point of the system carbondioxide level, motion level, fuel consumption, electrical consumption,fuel price, and electrical energy prices in real time.

The system further includes a central thermal recovery unit 206 insignal communication with the at least one controller 202 and the atleast one sensor 204. The central thermal recovery unit 206 isconfigured for determining an operating instruction based on the atleast one environmental measurement and system-related data receivedfrom the at least one sensor. The central thermal recovery unit 206 isfurther configured to transmit the operating instruction to the at leastone controller 204. The operating instruction includes a specificoperation sequence of a series of operating components/zones controlledby the at least one controller.

The central thermal recovery unit 206 can also be configured todetermine operating instruction based on environment measurements andsystem related data retrieved from a third party database 208. Forexample, the third party database 208 can include information such asweather conditions, user preferred comfort level, fuel cost, airquality, and the like. The information can facilitate the centralthermal recovery unit 206 to determine the operating instruction thatimproves efficiency and extends the life of the equipment and componentsof the system.

The at least one controller 202 and/or the at least one sensor 204 canalso be used to detect potential issues concerning certain mechanicalpart and/or zones of the system and transmit these issues to the centralthermal recovery unit 206. For example, the at least one controller 202and/or the at least one sensor 204 can detect a depleted refrigerantand/or leaks at a specific location within the system. The centralthermal recovery unit 206 can in turn determine parts in need of repairor replacement and repair or replacement sequences.

The central thermal recovery unit 206 can be configured to determine theoperating instructions (e.g., temporal operating sequence) using anadaptive learning method. For example, the central thermal recovery unit206 can record and analyze operation patterns, compare the efficienciesof each operation pattern, and on this basis predict the most efficientsequence under certain environmental/system conditions. The adaptivelearning method will make the heat recovery system more efficient fromthe continuous determination and implementation of a more efficientoperation pattern. The central thermal recovery unit 206 will enable aconventional HVAC system to achieve dramatically higher efficiencylevels. As an example, the operation pattern can include motor runningtime, internal and external temperatures and pressures, fuel combustionrate, fan speed and durations, inducer flow level, blower pressures andspeed, ignition timing, and the like. The operation patterns that resultin high efficiency can then be transmitted and shared with other thermalrecovery units via a network.

The central thermal recovery unit 206 can be configured to achieve thehighest system efficiency under given conditions. For example, if theprice of fuel depends on the time of day, the central thermal recoveryunit can account for fuel price to calculate system efficiency. Asanother example, for a system that can operate on certain cycles ofeither refrigeration or fossil fuels, if electric prices are moreadvantageous than natural gas at a certain time of the day, the systemcan favor operational cycles that use electricity over natural gas atthat time of the day.

The central thermal recovery unit 206 can also be configured to achievea balance between high system efficiency and low thermal pollutantrelease. For example, for a heat recovery system located in certainvalleys in certain states, for instance, Simi Valley, Calif., therelease of a certain pollutant will contribute to smog accumulation. Insuch cases, the system can be configured to monitor the release ofCO/CO2 and other system waste products and to balance energyconsumption, system efficiency and materials release accordingly.

As an example, given an outdoor temperature of 40° F., when a call forheat from a thermostat is received, the central thermal recovery unit206 will first instruct a controller 202 to open one or more dampers todraft in external air for beat extraction from a heat pump. This stepwill allow the system to deliver a desired amount of heat without theneed for a fossil fuel burn. If the first step does not achieve thethermostat setting within a defined period of time, the central thermalrecovery unit 206 will instruct one or more dampers to be closed and acombustion chamber to be activated to begin generating thermal energy byburning a fuel. When the thermostat setting is achieved, informationsuch as temperature in the return duct flow, exterior temperature,humidity, dew points, fuel consumption, run time, and the like will bemeasured, logged and transmitted to the central thermal recovery unit206 and/or a data collection center. These data are then analyzed todetermine, for example, the time period needed to activate a combustionchamber to achieve a desired temperature setting. The central thermalrecovery unit 206 can compare present operating conditions with previousoperating cycles under similar operating conditions and determine anoperating sequence to activate and/or deactivate certain operatingcomponents of the system.

As another example, when a call for heat from a thermostat received, thecentral thermal recovery unit 206 will determine the outdoor temperatureand humidity, internal and external system condition, combustion chambercondition to determine the starting time and duration burn cycles andinducer drafting cycles to achieve maximum efficiency of the system.

As another example, for a refrigeration system, the central thermalrecovery unit 206 can programmed to collect operating data andenvironment data of the system on a periodic basis and respond withoperation instructions. The operating instructions can include asequence and duration for operating a compressor, an evaporator, acondenser and a pressure device. Slight changes in the operating timesand pressures of specific components will increase the efficiency ofheat transfer and decrease the stress on system components. Subtlechanges in the operation of each component under specific internal andexternal conditions can lead to significant improvements in the abilityof the system to extract and transfer thermal energy.

The central thermal recovery unit 206 can also be in signal transmissionwith one or more personal devices 210, a display terminal 212, a userinterface 214 (e.g., a website), and the like, for receiving and/ordisplaying system operation parameters, climate conditions, and/or userpreferences. The thermal recovery unit 206 operate at differentlocations and environmental conditions can continuously transmit data toand receive data from the user interface 214 (e.g., a website). The datainput from various central thermal recovery units 206 are displayed onthe user interface (e.g., a website) and updated periodically. As aresult, the central thermal recovery units 206 installed throughout theworld can become more and more efficient by learning operatingparameters from other thermal recovery units.

The central thermal recovery unit 206 is configured to communicate thepersonal devices 210, the display terminal 212 and/or a user interface214 via a network 216 using a variety of transmission paths, includingwireless links such as radio frequency, satellite, Bluetooth and/orphysical links such as fiber optic cable, coaxial cable, Ethernet cable,and the like.

Referring to FIG. 20, the central thermal recovery system 206 includes aprocessor 218 for receiving and processing system related data such asoperation parameters, sensor measurements, climate conditions, fuelinformation (e.g., fuel price, fuel consumption, etc.). The processor218 can be also configured to output information such as operatinginstructions, system efficiency report, system pollutant release report,system operation history and analysis, and the like. This informationcan be stored in the database 220.

FIG. 21 illustrates a block diagram of an example heat recovery systememploying a central thermal recovery unit 206, a plurality ofcontrollers 202, and a plurality of sensors 204 to improve the operatingefficiency of the system. The sensors 204 are configured to receiveinformation such as outdoor temperature, suction temperature, plenumtemperature, air quality parameters, motor operation parameters and thelike. The plurality of controllers 202 are configured to receiveoperating instructions including operating one or more system componentsin a specific temporal sequence. In the depicted embodiment, the systemcomponents coupled to controllers 202 includes a blower, a heat coil, acompressor, a capacitor, and an inductor. The central thermal recoveryunit 206 can also be equipped with a sound warning and/or a lightwarning when potential issues are detected.

FIGS. 22-2 illustrate sample user interfaces for input system relatedinformation.

FIGS. 24-26 illustrate sample system operating parameters andstatistics.

It should be understood that the foregoing description is onlyillustrative of the aspects of the disclosed embodiment. Variousalternatives and modifications can be devised by those skilled in theart without departing from the aspects of the disclosed embodiment.Accordingly, the aspects of the disclosed embodiment are intended toembrace all such alternatives, modifications and variances that fallwithin the scope of the appended claims. Further, the mere fact thatdifferent features are recited in mutually different dependent orindependent claims does not indicate that a combination of thesefeatures cannot be advantageously used, such a combination remainingwithin the scope of the aspects of the invention.

What is claimed is:
 1. A heat recovery system in a habitat comprising: achamber including a cooling intake, an emissions intake and a chamberexhaust, the emissions intake is configured for receiving exhaust gasemitted as a result of fuel combustion in the furnace and the chamberexhaust is configured to discharge emissions from the chamber; a heatrecovery exchanger disposed within the chamber for contacting a mixtureof cooling gas introduced through the cooling intake and the exhaust gasintroduced through the emissions intake such that heat exchange iseffected; at least one fluid circuit in communication with the heatrecovery exchanger; a heat extraction exchanger in fluid communicationwith the heat recovery exchanger through the at least one fluid circuitto effect heat exchange between the heat extraction exchanger and anairstream running therethrough; at least one controller operably linkedto at least one operating component of the heat recovery system; atleast one sensor configured to collect and transmit at least oneenvironmental measurement and system related data from within thehabitat; a central thermal recovery unit in signal communication withthe at least one controller and the at least one sensor and configuredfor: determining an operating instruction based on the at least oneenvironmental measurement and system related data received from the atleast one sensor; and tray transmitting the operating instruction to theat least one controller.
 2. The system of claim 1, wherein the operatinginstruction comprises a specific operation sequence of the operatingcomponents connected to the at least one controller.
 3. The system ofclaim 1, wherein the operating instruction determined based on achievinga highest system efficiency.
 4. The system of claim 1, wherein theoperating instruction determined to achieve a balance of high efficiencyand low thermal pollutant release.
 5. The system of claim 1, wherein thecentral thermal recovery unit is configured to determine the operatinginstruction using adaptive learning process.
 6. The system of claim 1,wherein the operating component controlled by the at least onecontroller pc comprises a compressor, a condenser, a meter, a fan, ahumidifier, a pump, a motor, valve, a switch, a rotor, a capacitor, anda conductor.
 7. The system of claim 1, further comprising a third partydatabase, and wherein the operating instruction is further based on dataretrieved from the third party database.
 8. The system of claim 1,wherein the central thermal recovery unit is in signaling communicationto a smart device for receiving and displaying at least one operatingparameter, climate information, user preference, and potential systemissues.
 9. The system of claim 1, wherein the environment measurementand the system related data comprises temperature and pressure atspecific point of the system, humidity, barometric pressures, dewpoints, wind direction, geographical location and elevation of thesystem, temperature in the habitat, thermostats settings, chemicalbreakdown, fuel consumption, electrical consumption, fuel price andelectrical energy prices in real time.
 10. The heat recovery system ofclaim 1, wherein the heat recovery exchanger and the heat extractionexchanger comprise a multi-stage heat exchange system including atleast: a first stage having a primary heat recovery exchanger elementand a primary heat extraction exchanger element communicably coupled toeach other through a primary fluid circuit of the at least one fluidcircuit; and a second stage having a secondary heat recovery exchangerelement and a secondary heat extraction exchanger element communicablycoupled to each other through a secondary fluid circuit of the at leastone fluid circuit.
 11. A method of controlling a heating, ventilationand air conditioning (HVAC) system of a habitat, the method comprising:providing at least one sensor for receiving at, least one environmentalmeasurement and system related data within the habitat; providing atleast one controller opera y inked to at least one operating componentof the HVAC system; providing a central thermal recovery unit in signalcommunication with the at least one controller and the at least onesensor; determining an operating instruction via the central thermalrecovery unit based on the at least one environmental measurement andsystem related data; and transmitting the operating instruction to theat least one controller, wherein the operating instruction comprises aspecific operation sequence of the operating components connected to theat least one controller.
 12. The method of claim 11, wherein theoperating instruction is determined based on achieving a highest systemefficiency.
 13. The method of claim 11, wherein the operatinginstruction is determined to achieve a balance of high efficiency andlow thermal pollutant release.
 14. The method of claim 11, furthercomprising retrieving or storing data related to the parameters to athird party database.
 15. The method of claim 11, further comprising,transmitting to and receiving from at least one operating parameter,climate information, user preference, and potential system issuesrelated to the system to a smart device.
 16. A method for recoveringheat in a habitat, the method comprising: providing a chamber includinga cooling intake, an emissions intake and a chamber exhaust, where theemissions intake receives exhaust gas emitted as a result of fuelcombustion in the furnace and the chamber exhaust discharges emissionsfrom the chamber; providing a heat recovery exchanger disposed withinthe chamber for contacting a mixture of cooling gas introduced throughthe cooling intake and the exhaust gas introduced through the emissionsintake such that heat exchange is effected; providing a heat extractionexchanger in fluid communication with the heat recovery exchangerthrough at least one fluid circuit for effecting heat exchange betweenthe heat extraction exchanger and an airstream running therethrough;providing at least one sensor for receiving at least one environmentalmeasurement and system related data within the habitat; providing atleast one controller operably linked to at least one operating componentof the chamber, the heat recovery exchanger, and the heat extractionexchanger; providing a central thermal recovery unit in signalcommunication with the at least one controller and the at least onesensor; determining an operating instruction via the central thermalrecovery unit based on the at least one environmental measurement andsystem related data; and transmitting the operating instruction to theat least one controller, wherein the operating instruction comprises aspecific operation sequence of the operating components connected to theat least one controller.
 17. The method of claim 16, wherein theoperating instruction is determined based on ac hie it g a highestsystem efficiency
 18. The method of claim 16, wherein the operatinginstruction is determined to achieve a balance of high efficiency andlow thermal pollutant release.
 19. The method of claim 16, furthercomprising transmitting and storing system operating parameters to athird party database.
 20. The method of claim 16, further comprisingtransmitting and receiving at least one operating parameter, climateinformation, user preference, and potential system issues related to thesystem to a smart device. 7